95 explorer 4LOW not working, 4AUTO works, new shift motor | Ford Explorer Forums

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95 explorer 4LOW not working, 4AUTO works, new shift motor

silver70

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Joined
October 26, 2011
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City, State
Phoenix, AZ
Year, Model & Trim Level
'95 Explorer EB
Hi guys. Just joined and was directed here for my question after saying "hi" in the "new members forum." It's a doozy...

Vehicle: 1995 Explorer Eddied Bauer, pushrod 4.0L, 4R55E AT, BW 4405 control trac, 173,000 miles on vehicle; 65,000 on rebuilt motor; 70,000 on swapped transfer case; 70,000 on rebuilt tranny.

Issue: 4LOW light not working on instrument cluster and transfer case not engaging when dash switch is operated. 4AUTO works fine and all lights perform self-check upon startup.

What Works: Everything else. No warning or flashing lights come on during operation except the "check engine" light (oxygen sensor suspected culprit).

What's Been Checked: Proper 4WD engagement procedure (complete stop, in neutral, foot on brake), "new" junkyard shift motor (inspected for wear and bushing failure prior to installation), GEM module and connections visually inspected for corrosion, damage, etc., all fuses/relays.

Rogue Concerns: 4WD worked fine several months ago. One day, it took several flicks of the dash switch to get it to engage, and later, disengage. Also, the stock alarm sounds after using the key to open the door, even if I wait a little after unlocking the door to open it. Like, the alarm doesn't know the door has been unlocked. Door keypad disables the alarm fine, though. Also, the dome light remains lit even after entering and starting the vehicle. These issues lead me to believe the GEM is faulty, from what little I've read about it. Maybe even the neutral safety on the tranny.

However, I am not an "electrical" person. I have limited experience with an ohmmeter. I don't know how to test these things. I have rebuilt about half-a-dozen engines, transmissions, rear diffs, and all things mechanical over the years with zero issues. Electronics is a scary new frontier for me, though.

I've searched for quite a while and thought I'd finally break down and ask for help. Can anyone throw me a bone?

Thanks in advance guys,
Eric
 



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Are you in neutral with the foot on the brake when shifting into 4Low?
 






Please see "what's been checked" section. :D
 






have you tried banging on the shift motor while shifting it into 4low?
 






Yeah... gave her a few firm taps. Nada.
 






And you have tried manual engagement (using pliers, shift encoder dismounted)?
 






No, but the transfer case is in great shape and used to work just fine a few months ago. I guess I could try that to eliminate, for absolute sure, the transfer case being the problem.
 






Any ideas about the GEM, anyone? Do any of my symptoms point to that. No offense intended to anyone, but, I'm pretty much past the "bang on this/try vise-grips on that" stage. The mechanicals are all in working order. I suspect something electrical is to blame and I'm just looking for a more in-depth approach.

Thanks again guys,
Eric

P.S.- Sorry about the double-post.
 












Excellent! Thank you. I now have a starting point for the elctrical troubleshooting.
 






what is the actual motor that shifts the pin on the transfer case called? and how to you konw if it is bad or not?
 






what is the actual motor that shifts the pin on the transfer case called? and how to you konw if it is bad or not?

Shift Encoder. I think you can unbolt it so that you can see the "armature" and ground it against the case. Then have a helper run through the shift procedure from the cabin, while you check the function of the the motor. Do some searching in the Transfer Case sub-forum, there is a quite a lot of info there.
 






Shift Encoder. I think you can unbolt it so that you can see the "armature" and ground it against the case. Then have a helper run through the shift procedure from the cabin, while you check the function of the the motor. Do some searching in the Transfer Case sub-forum, there is a quite a lot of info there.

Im sorry what is an armature?
Ill start by replacing the switch and the Encoder before i go crazy.

Search isnt working for me right now it just comes up blank...im using firefox dunno whats wrong.
 






Im sorry what is an armature?
Ill start by replacing the switch and the Encoder before i go crazy.

Search isnt working for me right now it just comes up blank...im using firefox dunno whats wrong.

Sorry man, I know that is not the proper term, but I mean the part of the encoder that turns & engages the shift rod on the case.
Possible CTKI error.
 






DTS, are you talking about the shift motor? The blue plastic wire cover attached to the heavy cylindrical motor that bolts to the transfer case?
 






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