Need help swapping a transfer case.

[Sethro]

I'm in the middle of replacing my transfer case with one I ordered from a junkyard. I just realized that there is a brown wire that enters the case close to the rear driveshaft. On the one I just purchased, the wire has been cut flush with the case and there is no room to splice into it.

Does anyone know exactly which wire this is?

Do I have to split the case now?

Is it going to be difficult to split the case?

Any other suggestions?

Need help quick.

thanks

 

[Sethro]

can anyone just tell me what this wire is???

 

[Doug]

I beleive that's one of the wires for the hall effect sensors, you're probably going to have to order a new sensor from ford.

 

[cjbarron5]

yep and you will have to split the case and do some tear down to change it

 

[Sethro]

What is the hall effect sensor? Does it have to do with the torque on demand?

I took a solid core copper wire, cut at an angle so I had a sharp point, applied some heat and pushed it in between the existing wire and coating/grommet. Then I soldered and put a bunch of silicone around it so it wouldn't move.

I think it's going to work, but I'm curious to know what's going to happen if it comes off? Will I trip a code and lose 4x4, or will I be stranded?

 

[Doug]

It'll cause your 4wd to act up and not work properly. You need that sensor to be working. If what you did doesn't work your 4wd lights will flash at you.