4x4 trouble shooting

[Millerexplores]

Hey guys I recently purchased a '94 explorer xlt as a project to fix up and take to college. Recently I have been troubleshooting the 4x4 and I'm at a little bit of a loss. The wiring is good as the computer is receiving signals. I verified that the computer is functional and sending signals to the transfer case. I just replaced the shift motor with an OEM one and in the process found that the original was functioning but still replaced it anyway beens I had the new shift motor anyway. The only other thing in my mind it could be in the hubs. The automatic hubs had been replaced with Warn manual hubs before I got it. I was testing to make sure the hubs were functional. When only the drivers hub is locked the axel can still rotate freely which leads me to believe it is blown. The passenger side however does lock and does not allow the entire front axel to move. My next step is to replace the hubs, but I wanted to get some input before i drop a couple hundred bucks for new hubs.

 

[scottmi]

I made the change to the manual hubs years ago for the same usual reason, and have replaced the automatic shift motor. The Warn hubs do wear out and have had to replace them once already, and am thinking I may be due for replacement again. Pull your wheels off, pull the hubs and take a look at them. if in good order, good time to regrease. If splintered, replace.

 

[RangerX]

Here’s a great thread that may help How to: - 4x4 Troubleshooting guide

 

[Millerexplores]

I made the change to the manual hubs years ago for the same usual reason, and have replaced the automatic shift motor. The Warn hubs do wear out and have had to replace them once already, and am thinking I may be due for replacement again. Pull your wheels off, pull the hubs and take a look at them. if in good order, good time to regrease. If splintered, replace.

Thanks for the advice, I'll check them out.

 

[Millerexplores]

Here’s a great thread that may help How to: - 4x4 Troubleshooting guide

thank you, that's what I had been referencing previously while trouble shooting. With only one of the hubs appearing to totally lock the front axel I wasn't sure if that would cause the system to not work entirely. The transfer case makes an audible thunk when put in 4 low, but it dosen't sound like anything out of the ordinary from my experience. Is there a chance that the whole transfer case is bad?

 

[410Fortune]

Remove the shift motor and shift the t case by hand with plyers
These transfer cases are pretty tough

The motor is usually the weak spot

The front hubs will not effect the shifting of the t case there are no connections, meaning the transfer case and shift controller have no idea if you have auto or manual hubs

Shifting by hand, Shifting the t case from 2 hi to 4 hi should be effortless, the shift from 4 hi to low range takes a bit more effort, you
Might have to wiggle the front driveshaft a bit to get the t case to allow the low range shift

 

[RangerX]

Try swapping the hubs side to side.