need help with '91 transfer case | Ford Explorer Forums - Serious Explorations

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need help with '91 transfer case

have2goski

Well-Known Member
Joined
May 25, 2003
Messages
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City, State
Columbus
Year, Model & Trim Level
'91 Eddie
I was working on my transfer case shift motor today and dropped it. Needless to say the only thing attached was the brown wire going into the transfer case.

This wire broke very close to the case housing, which tells me 2 things, 1st the wire was a bit corroded cause the shift motor wasn't all that heavy. And 2nd, I now have a problem.

I can't use a wire connector on it to hook the brown wire back up.

from what i can tell from the searches, this wire controls the electric clutch in the transfer case. Obviously this is something important and needs to be fixed.

Looking for ideas.....

I thought maybe i could solder the wire back onto the nub that is still there but not too sure how that is gonna work out upside down :confused:
 






You can get a manual transfer case and put in. My 91 would not come out of 4wd low when I bought it. I put a manual transfer case in and no more shift motor to mess up. Hope this helps, there are good threads about rebuilding the shift motor. To access the brown wire you may have to go inside the transfer case?
 






Sounds like pulling and splitting the case to me.
 






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