4 wheel drive is stuck on

[mdawg644]

I have a 91' XLT with the the great push button 4 wheel drive and auto locking hubs. Well the other day when i was wheeling i got it into 4H and when i pushed the button to turn it off, nothing happened, so now im stuck in 4H. i know its not the transfer case motor because it goes in and out of 4L. There is also a awful noise that comes from the front left tire when i turn just a little bit towards that way. Im not much of a mechanic but anything that would help me before i give up and bring it in for a great deal of money to be spent to repair it, would be helpful. Also anybody who has so prices on a conversion kit form auto locking hubs to manual woulb be great to.

 

[Robb]

Your auto hub(s) has probably crapped out. Warn makes manual hubs that directly swap for your autos. The hubs + install kits will run about $200-$220.

 

[Blee1099]

Here's a link if you need help regarding your hubs.. Dead Link Removed

 

[DeRocha]

Sorry to hear of you problems...I have a few questions.

When you say it won't come out of 4H is it because pressing the dash 4x4 button does nothing (4x4 stays lit up)?. Or is it the 4x4 lights go off but the X feels like it is still in 4x4?

 

[glfredrick]

Have you tried to pull the shift motor off the transfer case and shift it manually? That is pretty easy to do - it only takes removing 4 10mm bolts from where it fastens to the t-case (don't disconnect any wires at first). Then once it is off, you will see a triangualar shaped rod sticking out of the back of the t-case. Grab it with a pair of pliers (have someone IN the truck holidng the brakes on with the tranny in neutral and the engine running - and BE CAREFUL). Twist it clockwise until it doesn't go anymore to get into 2 high. Opposite to get into 4 high and 4 low. It turns easy (or at least it should) and you will feel it go through its detents. Then you can put the shift motor back in place.

 

[mdawg644]

when i press the 4x4 button nothing happens. nothing in the transfer case happens. makes no noise or anything.

 

[mdawg644]

and the light stays on and the 4 wheel is still in

 

[DeRocha]

Many times the shift motor and its sensor just need a few good hits with a rubber or dead blow hammer to jiggle their wires into making better contact. Check out the shift motor thread below, it has a lot of good info. I have pulled out my shift motor 5 times to get it going. It now works first time every time and is the original unit.

Shift Motor thread

 

[Raminator157]

It could be your transfer case. I know a couple of Explorer owners who have blown them. They were going about 50 MPH and switched it into 4WD and blew it.

 

[F14CRAZY]

It could be your transfer case. I know a couple of Explorer owners who have blown them. They were going about 50 MPH and switched it into 4WD and blew it.

I know this is the case and I do not engage it high speeds, but I'm pretty sure the manual and advertising say you can engage and disengage at speeds up to 55 mp...

 

[mdawg644]

i wasnt even moving when i engaged my 4x4. i dont do that becaus it because i dont trust the "shift on the go method." I had my front hubs checked and there going to be replaced with manual lockers. but when i got my mechanic to disengage them then tryed the 4 wheel button again, nothing happeed still stuck in 4H.

 

[DeRocha]

When you press the 4x4 button do you hear any relays clicking in the trunk area? When you push the 4x4 button (high or low) a signal is sent to the 4x4 control module in the rear trunk area. This module has relays whick will click when trying to activate the shift motor on the transfer case. You can try resetting the module (reset button on the bottom) (key=on).

 

[mdawg644]

hit the reset buttoin still didnt shift oput of 4 high. shift in and out of 4 low but thats it.

 

[glfredrick]

Two things you might try... the first worked for my Ranger once.

Disconnect the battery - allow it to be off for about 10-15 minutes, then reconnect it. This will reset the truck computer and GEM module, which may cure your issue.

Second thing, I mentioned earlier removing the shift motor off the transfer case... Try it - it is easy and you will eliminate the issue of the t-case sticking or the electronics messing up. It will take less than 10 minutes to pull the motor and shift the case by hand... No oil will come out - nothing will get screwed up - it is virtually impossible to make any mistakes - just pull that thing off (3 10 mm bolts hold it to the t-case, and another shorter 10 mm bold holds a support bracket. Don't clip or remove any wires - just let it dangle there - have someone try to push the shift buttons and see what the motor does while you watch - and also try shifting the t-case manually with a pliers by twisting the triangle shaped pin that sticks out. The t-case is even marked as to which direction it has to twist...

Until you do those two things, it is unlikely that you will make any real progress figuring out anything...

 

[DeRocha]

Ok, but I need to know if pushing the 4x4 dash button causes the relays in the rear to click. If they don't then the dash button is suspect. If they do click then the shift motor/position sensor is suspect..

Did you whack the shift motor with a rubber mallet?

 

[mdawg644]

ok tried the reset button and nothing happened. I here relays clicking in the back when i hit the 4L button but nothing happens no relays or anything clicks or happens when the 4H button is hit. going out right now to try the battery thing.

 

[mdawg644]

tried disconnecting the negative on the battery and that did nothing either going to take of the t-case tommorow morning. get back to you then.

 

[DeRocha]

The reset button and negative battery cable removal are used to reset the 4x4 module. Since your module is working for 4x4 Low then resetting is not going to do much. Did you hit the shift motor yet? Do you know where to hit? I as skeptical at first, but when my 4x4 stopped working on the trail a few hits jiggled things in place and I was good to go....

 

[mdawg644]

ya i beat the hell outta it with a rubber malet and the 4x4 is still on. i hit the motor from every angle.

 

[glfredrick]

If you hit it enough you will fracture the magnets inside the case (people forget to mention this). Ask me how I know... :fire:

Fractured magnets lead to a binding armature, which leads to the very expensive purchase of a new shift motor.

A "gentle tap" on the end of the housing might dislodge a sticking sensor but that is about all.