4wd not working

[CowboyPinky]

I have a 91 4.0 5sp I think it is a borg werner transfer case, but it all has 230,000 miles. The problem is that when I push the button for 4x4 hi, nothing happens. No light, no grinding, no nothin'. Does anyone have a clue?:redexp:

 

[Jon Boy]

The crappy stock vacuum "acuator" or however you spell it, mine did it at 110,000 miles and now its screwing up again next step manual hubs

 

[jimbo74]

well, does 4x4 engage at all? if nothing, than i would look at the shift motor being frozen or the relay for the 4x4 switch... the hubs would still allow the lights to turn on

 

[Crankcase]

I would always try simple stuff first.... Check the fuse and the switch itself, and make sure the connector hasn't come off the back of it.

 

[CowboyPinky]

Agree

I have checked the fuse(s) and the relay. Everything is plugged in and the wires aren't frayed. I agree that the light should come on if it was in the hubs. What is the easiest way to check the motor? Someone here at work told me to beat on it with a hammer while someone pushes the button (like on a starter), but I'm not sure.

 

[gorilla]

First, search for other posts on transfer case problems.

Second, if your truck is similar to mine you probably have the electronic shift acuator, not the vacuum actuator. That shift motor needs taken off and the terminals need the black "crud" lightly sanded off. The first set of terminals that need cleaned are right inside the cap on the end of the motor that connects directly to the transfer case. The second set of terminals are the brushes and the armachure that is actually inside the motor. You will need the take the motor apart to do that set. It is not that hard to do, you might need to sets of hands to get the armachure back into the casing though... Hope this helps

 

[CowboyPinky]

Thanks Gorilla;
Yesterday I was pointed to a cool site that gave me a lot of info...the same thing you said. I took the armature motor off, cleaned the outside a little, put it back on and drove around a bit. Bam (as Emril would say) I pushed the button and she fell right in...I was extatic. I am going to clean the whole thing thoroughly when I get a chance, and the hubs still don't work, but the t.c. and motor do. This is a big step. Next...manual hubs, lift, tires, A/C.

Thanks to all for all your help.

By the way, that site is:
Dead Link Removed

 

[gorilla]

That is the exact website I was thinking of... just could figure out where I had seen it!! Some of the guys at Ford will flatout tell you that the auto hubs are worth only about 50,000 miles after that you need new ones. Preferably the manual Warns...that is my suggestion. Lift and tires are easy, just need the money. A/C is fixed on my truck but it was quite the pain! Good Luck!

 

[CowboyPinky]

That is another beef with me...I know that Warn makes a good hub, but are they the only ones in the market for this application. Superwinch, MM, and any other ones that come up in a search on the internet don't have applications for the Ex. Its not that I have anything against Warn, I was just wondering if I had a choice?

 

[dejello]

Mile Marker, maybe others? I don't know yet