4x4 low on 2002 Sport Trac manual transmission

[spt87]

Hi all - I've looked thru many older threads but not found anything on this.

I have the 5 spd manual transmission on my 02 sport trac. To shift into 4wd low the tranny needs to be in neutral and the brake pressed. I'm doing that but it won't shift into 4x4 low. I've tried with clutch pedal pressed/not pressed as well. Shifts into/out of 4x4 high fine. I would suspect the shift motor but in my experience that would typically affect shifting into/out of 4x4 at all (high or low).

On the manual transmission, is there a sensor/switch indicating back to the GEM/shift controller that it is in neutral? I'm thinking that may be the problem as I had a rebuilt transmission put in the truck a while back and I'm thinking if that was not plugged in during the install. I rarely use 4x4 low but recently had a need for it and noticed the problem. If there is a connector for it anyone have a rough idea where it is? Thanks.

 

[Rick]

Check this thread, opposite problem, but may be the same solution.

2001 Explorer Sport Trac. Stuck in 4low

www.explorerforum.com

 

[JK080]

To answer the question there is no switch or sensor telling the computer if you are in neutral so the transfer case will go to 4low.

Not sure where the problem is, it could be with the shift motor on the transfer case or the transfer case itself might have a problem.

 

[Mbrooks420]

Does your transfer case actually shift into 4 high? On the second gen V6s they just power the transfer case clutch between 2wd/4auto and 4wd high. They only actually “shift” when going into low range.

 

[Pete Deering]

Hi all - I've looked thru many older threads but not found anything on this.

I have the 5 spd manual transmission on my 02 sport trac. To shift into 4wd low the tranny needs to be in neutral and the brake pressed. I'm doing that but it won't shift into 4x4 low. I've tried with clutch pedal pressed/not pressed as well. Shifts into/out of 4x4 high fine. I would suspect the shift motor but in my experience that would typically affect shifting into/out of 4x4 at all (high or low).

On the manual transmission, is there a sensor/switch indicating back to the GEM/shift controller that it is in neutral? I'm thinking that may be the problem as I had a rebuilt transmission put in the truck a while back and I'm thinking if that was not plugged in during the install. I rarely use 4x4 low but recently had a need for it and noticed the problem. If there is a connector for it anyone have a rough idea where it is? Thanks.

Yes, the switch needs adjustment. Also check the ground wire for the neutral switch, which I believe for your is located on the firewall stud need the pcu. Look to see if its green. If it is, then clean it.

• SECTION 308-07B: Transfer Case — Automatic Shift 2002 Explorer Sport/Sport Trac Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 02/22/2002 Electronic Shift Control System Four-wheel drive mode is selected using a rotary switch located on the instrument panel. With the vehicle ignition on, the on-board controller verifies and matches the transfer case shift motor position to the switch. To shift in and out of 4WD low, three conditions must be met. The automatic transmission must be in NEUTRAL or the manual clutch depressed. The brake must be applied. The vehicle speed must be less than 5 km/h (3 mph). Electric Shift Motor The motor assembly and connector, mounted externally on the transfer case cover, drives an electric shift cam (7F063) which moves the lockup fork (7289) and the reduction fork assembly (7289) to the selected vehicle drive position. An integralposition sensor provides information to the electronic module on the current motor position. Digital Transmission Range (DTR) Sensor The DTR sensor is located on the outside of the transmission at the manual lever. The DTR sensor completes the start circuit in PARK and NEUTRAL, the reversing lamp circuit in reverse and the neutral sense circuit (4x4 only) in NEUTRAL. The DTRsensor

 

[Pete Deering]

Yes, the switch needs adjustment.

• SECTION 308-07B: Transfer Case — Automatic Shift 2002 Explorer Sport/Sport Trac Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 02/22/2002 Electronic Shift Control System Four-wheel drive mode is selected using a rotary switch located on the instrument panel. With the vehicle ignition on, the on-board controller verifies and matches the transfer case shift motor position to the switch. To shift in and out of 4WD low, three conditions must be met. The automatic transmission must be in NEUTRAL or the manual clutch depressed. The brake must be applied. The vehicle speed must be less than 5 km/h (3 mph). Electric Shift Motor The motor assembly and connector, mounted externally on the transfer case cover, drives an electric shift cam (7F063) which moves the lockup fork (7289) and the reduction fork assembly (7289) to the selected vehicle drive position. An integralposition sensor provides information to the electronic module on the current motor position. Digital Transmission Range (DTR) Sensor The DTR sensor is located on the outside of the transmission at the manual lever. The DTR sensor completes the start circuit in PARK and NEUTRAL, the reversing lamp circuit in reverse and the neutral sense circuit (4x4 only) in NEUTRAL. The DTRsensor

 

[Mbrooks420]

Yes, the switch needs adjustment.

• SECTION 308-07B: Transfer Case — Automatic Shift 2002 Explorer Sport/Sport Trac Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 02/22/2002 Electronic Shift Control System Four-wheel drive mode is selected using a rotary switch located on the instrument panel. With the vehicle ignition on, the on-board controller verifies and matches the transfer case shift motor position to the switch. To shift in and out of 4WD low, three conditions must be met. The automatic transmission must be in NEUTRAL or the manual clutch depressed. The brake must be applied. The vehicle speed must be less than 5 km/h (3 mph). Electric Shift Motor The motor assembly and connector, mounted externally on the transfer case cover, drives an electric shift cam (7F063) which moves the lockup fork (7289) and the reduction fork assembly (7289) to the selected vehicle drive position. An integralposition sensor provides information to the electronic module on the current motor position. Digital Transmission Range (DTR) Sensor The DTR sensor is located on the outside of the transmission at the manual lever. The DTR sensor completes the start circuit in PARK and NEUTRAL, the reversing lamp circuit in reverse and the neutral sense circuit (4x4 only) in NEUTRAL. The DTRsensor

It’s not a switch issue. If it was the truck wouldn’t start.

 

[Fire]

Looks like the comments are for an automatic transm. I have the 5spd manual and 4x4. IT wont go 4x4 Lo unless speed 0, brake on, and maybe in neutral. I would check the brake switch on the pedal.

 

[Pete Deering]

It’s not a switch issue. If it was the truck wouldn’t start.

Wrong

 

[Pete Deering]

Looks like the comments are for an automatic transm. I have the 5spd manual and 4x4. IT wont go 4x4 Lo unless speed 0, brake on, and maybe in neutral. I would check the brake switch on the pedal.

The brake switch can be check with a scan tool. Also you have to step on the petal to shift out of gear. By doing so, i believe that also check the switch.