94 stuck in 4X4

[MONMIX]

We have a 94 Ex in the shop.

Put a new knuckle, hub and roter on the left front.
( wheel came off zooming down the highway )
Obviously the customer swears it all worked before.

the 4X4 light stays on.
It wont shut off, how ever both front wheels spin free by hand.

It has auto lock hubs.

I am going to assume it is NOT in the drive train we replaced, but further up the line.
Any thoughts ?

Moderators: Please leave this in 911.
This vehicle needs to leve the shop by Monday.

 

[DeRocha]

I am assuming you have cycled 4x4 on and off several times correct? Which light is coming on (the one next to the button, Dash, or both?). Did you reset the 4x4 control module in the rear access panel?

Whenever it gets cold, the lights next to the buttons will kind of light up in my '93. 4x4 is not engaged at all, and the buttons are only dimly lit. Once I activate 4x4 and then deactivate it the light usually goes out.

 

[DeRocha]

You are correct. The drive train has nothing to do with the 4x4 indicator lights. These indicators are controlled by the 4x4 dash switch, controller module, and T-case shift motor position sensor.

 

[MONMIX]

repeated button hits yielded zero action what so ever.
The light next to the button stayed lit and that is about the end of that.
What about this contorl module in the rear panel ?

Okay, so far it sound like it is not an accident related issue. Toss it to the insurance company and let them decide what to do.

The more facts I have to back me up the better.
I appriciate your input

 

[MrShorty]

You said the wheels spin freely (indicating that the auto hubs aren't engaged), but does the front driveshaft spin freely? or does it appear locked at the t-case?

 

[88vert]

Have you tried resetting the computer?

 

[Robb]

I know you asked for this not to be moved, but I have to. If it were your Explorer, it would be a different story. I have to follow the rules also, and a problem with one of your shop's customer's vehicles just doesn't belong here.

Don't hate me....................

 

[Crankcase]

I would think the shift motor is stuck in 4x4 mode....

 

[Robb]

............to follow Crankcase's way of thinking, I would remove the t-case shift motor and see what position the t-case actually is in.

 

[RandyD]

I broke a hub in my 94 and put Warn locking hubs on. It still wouldn't go into 4x4. Go to:
Dead Link Removed

It turns out that the shifter motor was dirty, out of time and the plastic stop had broke. I don't know why it happended at the same time the hub broke. Even though your light is on, it may still have something to do with the shift motor being out of time.

There are a lot of good threads on here on this Forum.

RandyD

 

[DeRocha]

Checking the 4x4 module (rear trunk).
Unplug the two connectors that plug directly into the module (left side), turn the key on and push the button on the module. The LED should flash four or five times and stop. If the LED flashed the four or five times, the module believes it is okay internally, and youll need to check the external parts like the 4X4 switch, shift motor, magnetic clutch and wiring harness. If the LED did not flash at all or kept flashing continually, the module is telling you that it is damaged internally. (check for power & ground).

I would guess 99% of the time it is the shift motor. The shift motor is actually 2 parts. The worm driven motor and the geared positon sensor. The Position sensor is notorious for getting "lost". This occurs because the plastic stop inside the sensor breaks apart over time and allows the sensor to travel slightly outside its operating range. If this happens then the the 4x4 computer module next to rear washer fluid reservoir will have no idea what position the T-cases is in and will shut down and do nothing.

You should read the info on the edu site and then take the wire harness off the shift motor and test for 4H continuity among the various pins.

Dead Link Removed

 

[G-rigged]

Mine done the same thing but in 2wd. I took the switch out and crossed 2 terminals of the harness that goes into the switch and it kicked it in 4wd. So it was just the switch... 30 bucks on ebay later i had 4wd. In the mean time i used a piece of wire with stripped shielding on both ends and crossed the opposite terminals of the harness to take it in and out of 4wd. However i do not recommend this. I would try the switch....dont dig yourself too deep too soon. Check the easy stuff first. A dealer wanted 120 for the same switch.

 

[MONMIX]

Robb,
No worries man. You aughta' know me. I'll play by the rules too.

From the sounds of things the customer is trying to get some thing for nothing.

I will attempt some of these solutions, try to make the customer happy.

I'll keep ya'll in the loop

 

[MONMIX]

well here are the results.
Due to the age of the vehicle and the 170,000 on the odo, the insurance company is refusing to pay for further testing and diagnosing.
The customer as well is unwilling to pursue this any further.
I took the wheel off again and crossed my T's and dotted my i's took it for a test drive and found the vehicle was otherwise fully functional.
It is leaving Monday.

 

[88vert]

Are they selling it?

 

[MONMIX]

no clue

the out side is in pretty respectable shape.
the interior is gross
we also put on a new rear lift gate
and a bumper.

You do know how far Maryland is from Iowa don't you ?