4x4 Not engaging issue (4x4 lights after start) (Solved)

[Travis1992]

2001 Ford Explorer Sport 4.0 SOHC 6 cyl 185K miles

I was having an issue with my 4x4 not engaging using the switch on the dash. My lights would turn on after start(only, not before, which i guess is normal). I am pretty sure this means the 4x4 electronic module (TM101) is working, after I figured out the problem. I had replaced this module before when I purchased the vehicle, so I figured it might have had an issue again. I replaced it and had no success. I replaced the switch on the dash with no success.

I searched around the forums for my exact issue and it was hard to tell what mine was, since I did not hear any clicking in the 4x4 electronic module when I switched to 4high.

I ordered a new Transfer Case Motor which should arrive tomorrow. Through some research, I believe this is the correct one for my vehicle: Doorman 600-926. Amazon says it doesn't fit, but other places do. Maybe someone can confirm this for me before I put it in.

Today I beat on my old one with a metal hammer while it was in 4H and switched it back and forth a few times. It seemed to free it up, so this indeed confirmed it was the old/current Transfer Case Motor. I put in the old 4x4 electronic module and that also works fine. Clicks as normal.

I am putting this post in here so someone like me has another source of information to use. I will be replacing my Transfer Case Motor soon out of lack of trust, but carrying a hammer around and trying that if you need to rely on it or have issues is something to consider. I do not use my 4x4 much and the whole unit and under body is in really good condition with very little to no surface rust.

If someone who has replaced their Transfer Case Motor with the same vehicle with the Doorman 600-926, please let me know. I am probably going to wait a couple weeks to put it in.

 

[Fix4Dirt]

2001 Ford Explorer Sport 4.0 SOHC 6 cyl 185K miles

I was having an issue with my 4x4 not engaging using the switch on the dash. My lights would turn on after start(only, not before, which i guess is normal). I am pretty sure this means the 4x4 electronic module (TM101) is working, after I figured out the problem. I had replaced this module before when I purchased the vehicle, so I figured it might have had an issue again. I replaced it and had no success. I replaced the switch on the dash with no success.

I searched around the forums for my exact issue and it was hard to tell what mine was, since I did not hear any clicking in the 4x4 electronic module when I switched to 4high.

I ordered a new Transfer Case Motor which should arrive tomorrow. Through some research, I believe this is the correct one for my vehicle: Doorman 600-926. Amazon says it doesn't fit, but other places do. Maybe someone can confirm this for me before I put it in.

Today I beat on my old one with a metal hammer while it was in 4H and switched it back and forth a few times. It seemed to free it up, so this indeed confirmed it was the old/current Transfer Case Motor. I put in the old 4x4 electronic module and that also works fine. Clicks as normal.

I am putting this post in here so someone like me has another source of information to use. I will be replacing my Transfer Case Motor soon out of lack of trust, but carrying a hammer around and trying that if you need to rely on it or have issues is something to consider. I do not use my 4x4 much and the whole unit and under body is in really good condition with very little to no surface rust.

If someone who has replaced their Transfer Case Motor with the same vehicle with the Doorman 600-926, please let me know. I am probably going to wait a couple weeks to put it in.

cool, thanks for this post! havent used rhe dorman one myself

 

[Travis1992]

Just to follow up on this. I am having the same issue again. The Doorman 600-926 was not the correct unit, and I just used mine since it seemed to be working again. Now it will not seem to move, so I am going to try to get one from amazon that has no real good information on it. Wish me luck. If someone has a better source for this transfer case motor, please let me know.

 

[Travis1992]

Just to follow up on this. I am having the same issue again. The Doorman 600-926 was not the correct unit, and I just used mine since it seemed to be working again. Now it will not seem to move, so I am going to try to get one from amazon that has no real good information on it. Wish me luck. If someone has a better source for this transfer case motor, please let me know.

I opened up the transfer case motor to find out the magnet on one half of the inside walls was completely sheered off. This could possibly be from hitting it with a hammer, but I think I found my issue for sure. Now to wait for a new one, which seems to be difficult to find.

 

[J_C]

Do you mean that it does not shift into 4 high, or does shift into 4 high but not 4 low, or does shift into low but then it is only the rear wheels engaged?

The transfer case shift motor has no part in shifting into 4 high. That is all the electromagnetic clutch, it determines if the front wheels are engaged, or in Auto mode, what % of engagement based on sensed transfer case shaft speed difference. If the problem is not shifting into 4 high then I'd check for 12V on the brown wire coming from the torque on demand relay (electronic relay box) behind (and to the left of?) the radio. Wiring diagram attached.

 

[Travis1992]

Do you mean that it does not shift into 4 high, or does shift into 4 high but not 4 low, or does shift into low but then it is only the rear wheels engaged?

The transfer case shift motor has no part in shifting into 4 high. That is all the electromagnetic clutch, it determines if the front wheels are engaged, or in Auto mode, what % of engagement based on sensed transfer case shaft speed difference. If the problem is not shifting into 4 high then I'd check for 12V on the brown wire coming from the torque on demand relay (electronic relay box) behind (and to the left of?) the radio. Wiring diagram attached.

It does not shift into 4 high or 4 low. I do not have an "Auto" mode, and only a 2WD mode.
I determined the likely problem being the broken magnet in the Transfer Case Motor. I suspect this is causing the motor not to function properly(move at all) and my selection not being changed.

I will test other issues once I get a new Transfer Case Motor.

 

[J_C]

You do not even need a transfer case shift motor to go into 4WD High. That is mechanically speaking, IDK if some error would cause problems but from what I saw, there is no feedback to the BCM on whether it is doing that, so I doubt it.

A replacement transfer case shift motor will not solve not shifting into 4WD high unless something has changed that I'm not aware of. I would measure for 12V on the TC clutch wires and go from there.