4X4 problem

[dale5671]

Ok have had issues with the transfer case motor in the past. Tried the tapping on it trick and it worked for a while but it finally gave out on me this weekend right when we had a big snowstorm. Put a new one in. Never did it before but it didn't seem that bad.

But the problem now is it still isn't working. I think I got everything back together right. Didn't over torque the bolts and got the brown wire and blue/green wires back into the harness on the new one correctly. I can hear a click like it's coming from the new motor when I push the button on the dash. Then about five seconds later another click. No lights on dash or next to the button at all in anything I've tried yet.

Even did the test on the control module from instructions found in the excellent 4X4 troubleshooting thread in this great forum. Everything there checked out fine.

It's really confusing me because the last time it did this I took it to the shop and a new motor fixed everything for a long while, until now. Decided to try and save a little money and learn something and do the repair myself this time though.

Any ideas on what I should try and what my next course of action should be. Help from anyone here is greatly appreciated. Thanks.

 

[DeRocha]

From your description it sounds like your 4x4 computer, dash button, and related electronics are working correctly. You said the shift motor is new, but is it FACTORY new, a Rebuild, or junk yard replacement?

When you press the dash button the 4x4 computer in the rear hatch will energize the shift motor for about 5 seconds to shift it into 4H.. If the shift motor has the broken stop problem it can be jammed against the stop and the shift motor will not have the power to unjam itself so it ends up doing nothing.

 

[dale5671]

Factory rebuilt "new" right off the shelf at O'Reiley's automotive.

 

[Roadrunner777]

What did you buy, Cardone or Doorman? I kind of think you got a bad one. Is the new one acting like the old one did?

 

[DeRocha]

Did you try re-syncing the shift motor? If the shift motor mounting bolts were difficult to install it could mean they have jammed the Geared Position sensor against the Stop.

To re-sync the shift motor:

1. Mark the Geared Sensor cover to case
2. Remove the Shift Motor from the T-Case
3. Remove the Geared Sensor Cover
4. Remove the Geared Sensor
5. Turn the T-case selector shaft to 4H
6. Re-install the Shift Motor case (no bolts)
7. Re-install the geared sensor
8. Turn the shift motor case so it's bolts holes align with the T-Case (install bolts)
9. Ensure Geared Sensor is seated into housing (never force with cover)
10. Re-install the Geared Sensor cover

When you turn the truck on the 4x4 system will see the position somewhere in between 2H and 4H. When you press 4x4 it will move to the correct position.

Notes: If the Selector shaft was in 2H (default position) it could get jammed against the stop making it difficult to align and install the Shift motor mounting bolts. Placing the Selector shaft in 4H gives you a 1/2+ inch of play forward or back when installing the case allowing you to easily align and install the shift motor bolts.

If the Geared Sensor isn't seated all the way you can gently tap it in with a rubber/plastic mallet. Never try forcing it down with the cover as you'll damage its electrical contacts.