4x4 problems

[Ruben9237]

Hey everyone I’m running into a big issue with my 99 xl.about a year ago I did the brown wire mod because my wiring was fried and it worked great.we recently got snow here in North Carolina and my 4x4 was working great until today when I hit the switch for the brown wire mod my front tires no longer spins like they should I checked the wiring,bc axles ,front drive shaft and fluid in the t case and don’t see anything wrong.any help would be greatly appreciated

 

[joney]

Welcome to the forum, someone with experience no doubt has your answer! I thought the brown wire mod was FOR disconnecting power to the front wheels, so I'm no help here...

 

[EB4X]

Having a 95, with a true 2wd selection the brown wire mod has no bearing on me essentially, so no real experience/knowledge with it...but with mod main purpose is to gain true 2wd for 97's and up who don't have option..... when selector is set on 4auto....... are you stating when you "hit the switch" to manually enable (re-enable) Auto4wd that it no longer works....but manually turning selector dial to 4L or 4H is still working as they should...?

 

[Pete Deering]

Having a 95, with a true 2wd selection the brown wire mod has no bearing on me essentially, so no real experience/knowledge with it...but with mod main purpose is to gain true 2wd for 97's and up who don't have option..... when selector is set on 4auto....... are you stating when you "hit the switch" to manually enable (re-enable) Auto4wd that it no longer works....but manually turning selector dial to 4L or 4H is still working as they should...?

The front wheels are vacuum actuated. The brown wire controls the gearing in the tcase. Take a volt meter or a test light and check if there is voltage at the electrical solenoid in the engine compartment. They are both mounted together 95 is on the radiator support. I don't know where on the 99. Either on fire wall passenger side or driver side. Disconnect the electrical connector and test for voltage. Okay in the on position. In 2 wheel drive, one of the connectors will have voltage. The other ( 4 wheel solenoid) will not. Then turn or press the switch to 4 wheel, and check for voltage. The reserve of the first test. If you have voltage at each solenoid., that system is ok. Then check for vacuum at the solenoids. Start the car, and remove the hose conection, don't remember, I believe the top hose is the supply, or the bottom hose. Put your finger over the hose to feel for vacuum ( 4 wheel solenoid). If you have supply vacuum. Check for vacuum at the actuator. If you have hand vacuum pump check, if not go under car, at actuator, there are two vacuum switch there. Check for vacuum. And see if the actuator works. One Switch moves it in the 4 wheel position and the other moves it back to the 2 wheel drive position.

 

[EB4X]

"The front wheels are vacuum actuated." Not on his 99....he has a live front axle.
I think his contention should be his "4WD stopped working" ...unrelated to brown wire mod....of course since the OP is not responding to any posts we'll never get to the bottom of his issue.

 

[Mbrooks420]

Like mentioned above, thankfully they did away with the vacuum hubs after 1996. First thing to test is that there is voltage on the brown wire.

 

[Ruben9237]

Having a 95, with a true 2wd selection the brown wire mod has no bearing on me essentially, so no real experience/knowledge with it...but with mod main purpose is to gain true 2wd for 97's and up who don't have option..... when selector is set on 4auto....... are you stating when you "hit the switch" to manually enable (re-enable) Auto4wd that it no longer works....but manually turning selector dial to 4L or 4H is still working as they should...?

I did the brown wire mod because I saw a video on it after my wiring was fried and the 4x4 switch stoped working so I wired the brown wire to a switch that has 12v so when I hit it it would essentially “turn the front tires on” but I remember when I would hit it with the rear spinning I would feel the front tires engage and I would get I stucknow when I hit it I can feel it try to engage but front tires don’t spin

 

[Ruben9237]

The front wheels are vacuum actuated. The brown wire controls the gearing in the tcase. Take a volt meter or a test light and check if there is voltage at the electrical solenoid in the engine compartment. They are both mounted together 95 is on the radiator support. I don't know where on the 99. Either on fire wall passenger side or driver side. Disconnect the electrical connector and test for voltage. Okay in the on position. In 2 wheel drive, one of the connectors will have voltage. The other ( 4 wheel solenoid) will not. Then turn or press the switch to 4 wheel, and check for voltage. The reserve of the first test. If you have voltage at each solenoid., that system is ok. Then check for vacuum at the solenoids. Start the car, and remove the hose conection, don't remember, I believe the top hose is the supply, or the bottom hose. Put your finger over the hose to feel for vacuum ( 4 wheel solenoid). If you have supply vacuum. Check for vacuum at the actuator. If you have hand vacuum pump check, if not go under car, at actuator, there are two vacuum switch there. Check for vacuum. And see if the actuator works. One Switch moves it in the 4 wheel position and the other moves it back to the 2 wheel drive position.

I’ve been going crazy looking for a vacuum “box” on the front axle or around it and haven’t been able to find it at least I know why now because the 99 doesent have it but I think I’m going to drain fluid in the t case today and check it.I do remmeber I had a leak on one of the gaskets.hopefully it’s not bone dry. I will get back with everyone when I get off of work later.thank you guys for all the help so far I hope I don’t need a t case.

 

[Ruben9237]

I’ve been going crazy looking for a vacuum “box” on the front axle or around it and haven’t been able to find it at least I know why now because the 99 doesent have it but I think I’m going to drain fluid in the t case today and check it.I do remmeber I had a leak on one of the gaskets.hopefully it’s not bone dry. I will get back with everyone when I get off of work later.thank you guys for all the help so far I hope I don’t need a t case.

 

[Ruben9237]

View attachment 425569

I added a picture of my explorer because I know you guys like to see what your helping

Having a 95, with a true 2wd selection the brown wire mod has no bearing on me essentially, so no real experience/knowledge with it...but with mod main purpose is to gain true 2wd for 97's and up who don't have option..... when selector is set on 4auto....... are you stating when you "hit the switch" to manually enable (re-enable) Auto4wd that it no longer works....but manually turning selector dial to 4L or 4H is still working as they should...?

yes

 

[Mbrooks420]

If you’ve been engaging 4wd with the rears slipping you’ll be needing a new t case before too long.

 

[Ruben9237]

If you’ve been engaging 4wd with the rears slipping you’ll need a new t case.

If you’ve been engaging 4wd with the rears slipping you’ll need a new t case.

I’ve heard something about a coil clutch or something like lay inside the t case that actuated the front drive shaft how would I go about checking or changing that and when I say I engage 4x4 with the rear tires spinning I’m not meaning the gearing (4h or 4l).I’m talking about my switch I have for the brown wire.if I switch it on while rear are slipping it essentially is now in 4h

 

[Ruben9237]

If you’ve been engaging 4wd with the rears slipping you’ll be needing a new t case before too long.

I just priced one at my local junk year and they only want 150 but hopefully it’s now on fluid or something simple

 

[Pete Deering]

I just priced one at my local junk year and they only want 150 but hopefully it’s now on fluid or something simple

you are going all over the place. the TCase has nothing to do with the front wheel engaging( or locking into place). The Tcase just provides the gearing. the actuator is cover by a sheetmetal shield. Does 4 wheel high work( engage?

 

[Ruben9237]

you are going all over the place. the TCase has nothing to do with the front wheel engaging( or locking into place). The Tcase just provides the gearing. the actuator is cover by a sheetmetal shield.

Ok thanks for the info. So what would lock the front tires in

 

[Pete Deering]

Ok thanks for the info. So what would lock the front tires in

this lock front wheels

 

[Ruben9237]

this lock front wheels View attachment 425574

Ok where would this be located on my 99 because I can’t seem to find it

 

[Ruben9237]

Ok where would this be located on my 99 because I can’t seem to find it

Also I checked my front axle for vacuum lines and there are non just one vent hose on top near drivers side wheel

 

[EB4X]

So in ANY position you are not getting 4WD? (front tires spinning)....correct.... 4 Lo, 4 Hi and with brown wire setup for 4Auto... correct...?

 

[Ruben9237]

So in ANY position you are not getting 4WD?....correct.... 4 Lo, 4 Hi and with brown wire setup for 4Auto... correct...?

I’m getting like half of what I used to get I have the t case motor wired also to a 3 way toggle switch to turn it from 4hi to 4 lo and then the other brown wire switch is to “turn the front tires on” but my t case shift fine in and out of the 4lo gear just no spinning of the front tires I can feel it like 1/4 engage but I guess not enuf for the front tires to actually do anything