Another blinking 4X4 Light thread

[jrork]

Okay. I apologize for another thread but I can't seem to locate the actual fixes.

MY daughter has a Sport and the lights are blinking along with no 4X4. We did a quick disconnect of her battery and that fixed it for a couple days then it came back.

I've disconnected it again for approximately 20 minutes and sure enough. It appears to be working again.

Assuming it's issue comes back, what would be the next step? I see the large plug back by the transfer case but couldnt figure out how to unplug that thing for the life of me.

Thoughts and suggestions to help Ol Gramps out here?

Thanks a bunch!

 

[scucci]

Sounds like a transfer case shift motor or encoder problem. Usually pulling the motor/encoder and cleaning the armature, seating the brushes and lubing fixes this. The following threads are how to rebuild the motor and troubleshooting. Your shift motor is identical except that your encoder can not be disassembled. A shot of silicone lubricant where the encoder shaft comes out of the case and working it back and forth will free it up. This combined with the motor cleanup will usually get rid of the problem. There is a long complex trouble shooting list in the service manual that requires expensive diagnostic equipment. That is why the shift motor is the first thing to check.

4X4 Shift Motor Rebuild
http://www.explorerforum.com/forums/showthread.php?t=123542

4WD, AWD, and Transfer Case Information and Operation
http://www.explorerforum.com/forums/showthread.php?t=134671

The Borg Warner 4405 Transfer Case Rebuild Diary
http://www.explorerforum.com/forums/showthread.php?t=182071

2nd gen 4wd not working? A Troubleshooting How-To
http://www.explorerforum.com/forums/showthread.php?t=203441

 

[jrork]

Thanks so very much! That is exactly what I was looking for. Wish me luck!

 

[jamester_a]

Check hall sensors

Could be a buildup of metal dust on your sensors. Pull the one in your rear diff and those in the t-fer case themselves and wipe clean (one may be inaccessable under the motor, so just clean the other one as a start). A little bit of RTV to seal them back in place when re-installing. Reset GEM by pulling fuses or battery disconnect and drive it a few days including trying out the 4wd.

I would do this in addition (maybe before) addressing the motor. Given the age of your rig though, your motor may indeed be the root cause, but the sensors are a simpler thing to check first.