4X4 Issue help and input please!

[4x4navajo]

So I have the famous 4x4 not working issue on my 94 Navajo. Lights next to the 4x4 switch don't light up nor do I hear the relay click. The computer unit in the back panel driver side seems to be working fine though? Would this mean there is a possibility my switch is bad? Also thinking of running my own rocker switches to control 4x4 instead of the stock one, Any input or advice of why or why not to do it?

Thanks
-V

 

[Flip4ford]

your 4x4 motor is probably bad -- either rebuild it or replace it

 

[coco944x4s]

Try knocking on the shift motor with a hammer lightly and try it again, has worked for me in the past. The best thing to do in this instance is what a lot of folks over on therangerstation.com have done, and what i myself have done as well which is simply to replace the electric shift case with a manual shift case. I did and i have no complaints with having done it aside from i never redid the shifter plate so i get warm air in around the shifters, but i ran out of time and my dad got pretty mad that i had his garage tied up so long, so i decided to make him happy instead of taking longer.

 

[4x4navajo]

Thanks guys!
Coco944x4 that's what I originally wanted to do is it difficult to change it? Also how'd you run the manual 4x4 shifter and does it being manual effect the autolock hubs? If you could can you post pics of inside the vehicle so I can see placement thanks again!

 

[coco944x4s]

Please forgive the lateness of my reply, i am not on as often as i would like.

Its not hard at all, just like replacing a transmission or any other part, except this time your adding a little more. Disconnect the front and rear driveshafts from the transfer case. Support the transmission with a jack, remove the transmission cross member and mount. Lower the jack slightly so you can access all the nuts holding the transfer case to the tail housing of the transmission. Then just remove the transfer case. Reinstall the manual case in the reverse order.

Depending on whether you have an auto or manual transmission will dictate which shifter you need to buy, the shifter itself may be the same, but the bracket that bolts to the tail housing is a little different auto to 5-speed. To do it to where it looks right, you will need to remove your front seats, and console (if a Navajo has a console like the explorer) and pull the carpet back exposing the floor plate (silvery looking piece screwed to the floor on top of the transmission tunnel). Remove it, install the shifter, measure the shifter location to cut a whole in the floor plate, cut plate, drill holes for shifter boot, cut carpet for shifter, reinstall all parts, install shifter boot and trim. I know its a long process, but well worth it. Some of this will be different if you have a manual like I do. You will need to find a double manual shift bezel, and just put both shift boots in it. If you have a manual, you dont need to remove the seats and all, just trim the carpet and floor plate like I did after pulling the transmission shifter boot up.

 

[Naasau]

Coco is right, it is an awful lot of work and very taxing, but in the end is awesome.

If you want to try for a cheaper/faster solution though, I would suggest pulling the engagement motor and checking it for failure. The normal cause is actually quite simple, there is a rubber bushing inside the motor that acts as a bump stop for the locator wheel, and over time it hardens and eventually crumbles, then the motor doesn't know where it is and stops working. I pull mine out and replace that bushing (with a chunk of clear fuel line hose) every fall now, just until I can work up the cash and time to swap in a real manual case. It takes all of a half hour to roll under, pop connections, remove unit, dismantle, replace bushing, clean contacts etc, then slap it all back together. No big deal.

It was actually this issue and the solution thread to it that first brought me to this site. So if someone as inept and inexperienced as I was then can get it done, so can you!

 

[coco944x4s]

It wasnt that hard to me, but then again i have been working on tractors, lawn mowers, and cars/trucks for the last 16 years too. Just guage it by your comfort and skill level.

There are a few companys/individuals who have produced manual shifting mechanisms for the electric shift transfer case, do a google search or search on the site for it.

 

[92302expo]

What kind of t-case bolts up to the a4ld?

 

[4x4navajo]

Thanks again guys I think I'm gonna purchase the shifter from dandd-performance yet it is a little pricey but also heard that the popular shiftster is coming out with the shiftster 2 which will allow you to do the same thing as dannd performance's and allow you to shift into 4wd from inside the cab and should be priced significantly lower and is hoping to be out by thanksgiving so I'm going to hold off for that and just crawl under the vehicle to throw is in 4 until then.

What kind of t-case bolts up to the a4ld?

I believe it is a borg warner 1354 and they came electric or manual unfortunately I was stuck with the electric haha.