4x4 module may be bad

[jacobl]

I received a new 4x4 control module today from directfordparts.com. I am pretty sure they sent me the wrong one. It will put the truck in 4x4 high but the 4x4 auto doesn't work and it won't shift into 4x4 low. The 4x4 high light flashes 6 to 8 times every few minutes.
The part number on the invoice is different from the number on the module.
I emailed the website and they are telling me it is the right one and the number is only fords manufacture part number.
The truck is a 2002 xlt 4x4 v6 with 130k miles.

Thanks for your help!

 

[jacobl]

These are my part numbers
old module:1L24-7H473-AH

part number on invoice:1L2Z-7E453-A

new module:1L24-7H417-AL

I need to fix this for winter!

 

[jacobl]

I tried both of the modules again and they both will put the truck in 4x4 high and they won't put the truck in 4x4 low. They both flash 4x4 high light 6-8 times every 2 minutes and the auto 4x4 doesn't work.
could there be something else other than the 4x4 modules that would cause my problem?

 

[doubledflooring]

I'm not an expert by any means ... But have you serviced your Diffs and transfer case recently?

If not ... you may want to. It might fix the problem.

Also there is an acuator motor on the transfer case that could be the culprit.

If you remove it ... you can manually select 4x4 low and if it stays engaged then it's most likely that motor that needs replaced.

Ofcourse I'm speaking of my experience of earlier models ... not sure if the Acuator applies to you. But worth looking.

 

[gijoecam]

Yes, there are lots of other things that can cause the problem. For less than what you've already spent on the module, you could have had a Ford dealer scan the codes and pinpoint the problem. That's what the blinking lights indicate.

And no, AutoZone cannot retrieve those codes.

-Joe

 

[jacobl]

well I was told my new module is the right one again. The new module is a updated model. Since the truck does the same thing with the new module as it did with the old one. I'm thinking there is nothing wrong with my old one. Which sucks because there is a no return policy on electronic parts.

How much do you guys think it will cost to have the dealership take a look at the codes?
Thanks for your help.

 

[jacobl]

I got another email from directfordparts.com and The guy said he spoke to one of the mechanics and he said that the transfer case shift motor is not working and that causes the lights to blink.
Should I just rebuild the shifts motor? Has anyone rebuilt one on a 2002 explorer?

 

[gijoecam]

I don't doubt that they have superseded the part number to something more current. It's not uncommon.

Odds are, they're going to charge you an hour's labor to connect it and scan it, even though it takes longer to find it in the service lot and pul it into the service bay than it does to connect it, scan it, and determine the problem.

The typical charge in this area for them to evaluate it is an hour.

One cannot diagnose a transfer case shift motor over the phone. It's just not possible. Sure you can rebuild or replace the shift motor on an '02. A-1 Cardone does it all day long. But unless you know that the motor is bad, you're just wasting more time and money.

Now, I'm not saying that the tech is incorrect: A bad motor *can* cause the lights to blink... but so can a bad connection, or a broken wire, or a bad speed sensor, or a whole number of other things that aren't the motor.

Look at it this way: Say your furnace quits working. You can call a tech to come look at it, evaluate the problem, and fix what's broke. Or you could call a heating and cooling shop, the secretary can ask the technician what causes a furnace to break, and the tech can say 'The wiring from the fuse box could be bad.' You're not going to rewire the house to fix your furnace, are you?

 

[jacobl]

What is confusing me is that the 4x4 high will work. The 4x4 low doesn't work.
Doesn't the transfer case shift motor have to work to shift it in 4x4 high?

 

[gijoecam]

Not necessarily. I need to check the '02 service manual when I get to work, but I believe the '02 still uses the Torque On Demand system in the transfer case, which is basically an electro-mechanical ball-ramp clutch. In other words, an electronic lock. If that's the case for the '02s, it only uses the motor to engage and disengage the low range planetary gear set. Lockup is handled by the clutch.

 

[doubledflooring]

Yes ... but it is basically a 3 position switch motor and the low is known to go out.

If it is killing you to know ...

Crawl under the truck ... locate the transfer case ... directly behind the transmission.

the side facing the rear of the truck is where the shift motor is located ... there are three bolts in a triangular pattern on one side and one bracket on the cylinder side ... there is one plug ... remove all and you will see what the shift motor is turning ... there is a dial almost ... one position says 2h one says 4h the last says 4L .... if you have removed the motor turn the dial to 4L ... go start your truck .... and see if it stays there .... if so the motor is bad ....

now for the catch ... the one time I did this, I had my Ex on 4 jack stands (make sure if you have Air ride equipped that it is turned off) anyhow. Once I switched it to 4L and found it stayed there after starting the truck and putting it in gear. I had a hell of a time switching it back to 2H and installing the knew motor.

I'm sure there is an easier way to do this ... but I was 99% sure my motor was bad so I knew it had to come off anyhow.

Hope this helps

 

[doubledflooring]

http://www.explorerforum.com/forums/showthread.php?t=123542

Refer to the above thread for more indepth info ... I was wrong 8 bolts to remove

 

[jacobl]

http://www2.partstrain.com/v5/products.php?N=10333+4294967265+1616+4294966353

Are these transfer case motors any good?

I'm not sure if its the motor yet.....just looking at prices.

 

[doubledflooring]

Not sure ... I got one from the junk yard ... but next time I'll rebuild it like instructed in the thread i linked

 

[IZwack]

The question is, do you need 4LO? Because a majority of the people do not need 4LO. So forget about it if all you need is 4HI

 

[gijoecam]

Yes ... but it is basically a 3 position switch motor and the low is known to go out.

I'm afraid not. The second and early third-gen t-cases only use the motor to engage and disengage low range as I described above, just like your 44-05 case does.

Forgot I had an '02 manual here at home....

Mechanical Operation
The Borg-Warner 44-11 transfer case is available in the Explorer (A4WD) vehicle. The transfer case transfers power from the transmission to the rear axle, and also to the front axle when electronically activated.
In the Auto mode, torque from the transmission is transferred to the input shaft which, in turn, drives the rear output shaft that drives the rear axle assembly. The electromechanical ball ramp clutch assembly drives the drive sprocket after the 4x4 electronic module activates the clutch coil. The drive sprocket turns the drive chain that rotates the front output shaft and the front driveshaft. In the 4x4 High mode, the operation is the same as in the Auto mode, except that the 4x4 electronic module consistently activates the electromechanical ball ramp clutch assembly.
The high-low shift occurs when the reduction shift fork moves the high-low collar to lock the planetary gear set to the output shaft. Then, torque, transmitted through the sun gear, from the input shaft, turns the front planetary gear set assembly. The front planetary gear set assembly, which is now engaged, provides transfer case speed reduction.
Transfer Case Functions
There are three transfer case modes, Auto, 4x4 Low, and 4x4 High. Neutral is only available as a dealer installed option.
Control-Trac Function
The Control-Trac transfer case uses an electromechanical clutch assembly to control torque to the front wheels. In the Auto mode, while at rest and under cruising conditions, the 4x4 electronic module activates the transfer case clutch at a minimum level. This allows for the slight difference between the front and rear driveshafts which occurs normally when negotiating a corner on dry pavement. Under any of the following conditions, the 4x4 electronic module will increase the torque sent through the clutch to the front wheels in order to prevent or control slip.

• Slip is detected (by monitoring the front and rear OSS sensors in the transfer case)
• Throttle position (by using the throttle position signal from the PCM)

Range Function
NOTE: At zero throttle, the duty cycle remains low.
In the 4x4 Low Range, with throttle input, the transfer case electromechanical clutch locks the front and rear driveshafts for maximum 4x4 traction. The transfer case shift motor rotates the shift cam to move the reduction shift fork to the 4x4 Low range position. This low range shift, accomplished through a planetary gear set, changes the torque to the driveshaft from 1:1 to 2.48:1 ratio.
In the 4x4 High Range, with throttle input, the 4x4 electronic module signals the transfer case electromechanical clutch to lock the front and the rear driveshafts for maximum 4x4 traction. Never use the 4x4 High range or the 4x4 Low range when driving on dry or merely wet pavement. Use the 4x4 High range or the 4x4 Low range only for driving off-road or in severe winter weather.

In short, 4x4high does not use the motor. That's likely why it still works. However, that's still no confirmation that it's the shift motor throwing the fault code. Without knowing the fault code, it's a guessing game at best.

edit: And the transfer case motor on his is 4 bolts. Three in the mounting flange, and one in the motor support bracket.

 

[jacobl]

Since I'm in michigan and travel back roads in the winter.....I sometimes use 4x4 low. I don't need it most of the time....I just like to play in the snow. What i really want is the light to stop flashing and get everything working properly again.

I just want to say Thank You for your helpful fast replies

 

[IZwack]

Since I'm in michigan and travel back roads in the winter.....I sometimes use 4x4 low.

Next time, try to just use 4HI. 4LO is for torque multiplication like climbing up steel inclines. I wouldn't use 4LO on anything going faster than maybe 5-10 mph cauz there really is no need for that much torque if you're able to sustain that speed.

 

[jacobl]

I only use low when going through very deep snow for short periods. I don't go over 15 mph while it's in low.

 

[gijoecam]

Next time, try to just use 4HI. 4LO is for torque multiplication like climbing up steel inclines. I wouldn't use 4LO on anything going faster than maybe 5-10 mph cauz there really is no need for that much torque if you're able to sustain that speed.

Actually, I would beg to differ... There are more than a few occasions where high speeds in 4low are useful, and deep snow is one of them. Deep sand is one I use it for regularly as well. The torque multiplication greatly reduces the strain on the (not-so-strong-to-begin-with) transmission.

Besides, those of us masses still running the stock transfer case only have a 2.48:1 reduction, not the massive 4+:1s you crawlers have. (yeah, I'm jealous, so what??)