Never ending 4WD problem

[GaryGnu]

I've been having some problems with my 4WD system on my 1996 XLT for a few months. My problem was that I was getting an error code blinking shortly after I attempted to use it. Last month I got stuck. Very embarassing. I tried disconnecting the battery, and that didn't work. So, I took it to the Ford dealer. They wanted about $880 to replace both the 4WD motor and a sensor. They also "found" about $1000 more worth of problems with my truck (unrelated to the 4WD system), and I said "forget the whole thing". So I took the truck to my regular mechanic and he replaced the 4WD motor and sensor (and the other things also) for just over $600. Dealers are criminals!!

So, I drove the truck home from the mechanic, and in the 4WD Auto setting I once again was getting the 6 blinks on the 4WD lights after I got over 40MPH. I got to a straight part on a road (darn snow plows got rid of all the snow!) to test the 4WD Low setting. It seems to be operating correctly, but the lights still flash. I tried disconnecting the battery for awhile, and restested, and I STILL got the blinking error codes.

I think the 4WD system is operating correctly, but for some reason I'm still getting the error codes. Does this make any sense, or is something else still wrong.? This is very irritating, but this is the first problem I have ever had with this truck.

And BTW, no one has told me exactly what the code of 6 blinks actually indicates.

 

[Nate1]

Take it to autozone and get the codes read for free if you can. It will be much easier to solve if we have codes.

 

[GaryGnu]

I may have to do something like that. I fear my mechanic is going to tell me to take this back to the dealer. And I do not want to do that. What else could the problem be?

 

[TPLYNCH]

Probably the speed sensors are dirty or malfuctioning. Make sure everything is plugged back in on the T/F case too.

 

[Msupertek]

FORD CERTIFIED TECHNICIAN

I guess that makes me a criminal huh? If you only new and could see all the crap we fix for customers under warranty that we shouldn't. Oh and don't forget the times that a customer who comes in with all kinds of problems and DOES NEED a $1000 worth of work and we get the sob story of why he can't afford it, so I do some of the stuff that is simple for free because I FEEL SORRY for him. I GET PAID 100% COMMISION ON WHAT I REPAIR ONLY NO BASE PAY. That estimate made was to let ya know whats going on with your car, I make em all the time. It doesn't mean you have to buy it, its there so if a month down the road you break down. You won't say " I can't believe that dammed dealer didn't tell me my truck was in need of other repairs, they screwed me over". By the way, I performed about 2.5hrs of a repair for free the other day and gave the guy a free radiator for his X (that I had in my garage from mine before my mods began), after his sob story. I believed him and he was handy capped (no legs), felt bad for the guy. BUT I BET THERE IS SOMEBODY OUT THERE CALLING ME A CRIMINAL RIGHT KNOW BECAUSE THEY THINK I AM OVERPAID, REGARDLESS OF MY HONESTY AND INTEGRITY!

 

[oldskool95max]

Speaking of 4wd. I'm looking at buying an explorer myself. I am curious to know if, and what years/models have a switch that can turn of the 4WD so you can just be in 2WD, so that you are not sucking gas and relying too much on your 4WD? Or, is it always on no matter what, that'd kinda suck though??

 

[OZexplore]

I guess that makes me a criminal huh?

I think he was refering to DEALERS not mechanics because every mechanic that has worked on my cars over the years have been pretty good (some brilliant)
but i cant say that for all the dealers(any make) or the owners of some workshops.

 

[TPLYNCH]

95-96 are 2wd, 4auto & 4lo

97+ are 4auto, 4hi & 4lo. Switch can be installed to make it 2wd when in 4auto. Big long thread on how to do in this forum.

 

[GaryGnu]

Update on this... I took it back to my mechanic. I am also having a problem that in the 4WD Auto setting I am getting a cluncking sound when I turn corners, which tells me the 4WD is incorrectly engaging in the Auto setting. My mechanic says the dealer needs to program the GEM to fix this problem. He was unable to do it. Also, my 4WD lights still blink 6 times in the Auto setting after I get the truck above 40mph.

Short history of this is that I got my own mechanic to do the work the dealer wanted to do (replace 4WD sensor and 4WD motor) for less than half the price. The joke is partially on me because I've got to take it back to the dealer to get the GEM programmed.

To anyone familar with this type of problem, does this make sense that the GEM needs to be programmed to deal with the new sensor and motor that has been installed?

 

[tenikiwon]

To my knowledge you shouldn't have to reprogram after replacing those, but reprogramming and solve other known problems.

What did it cost to get it reprogrammed?

 

[Geoff123]

Speaking of getting GEM's reproramming

I have a '96 and i am 99% sure that my GEM hasnt been reprogrammed because it engages harshly. Will it cause any damage if it isnt reprogrammed?

Thanks
GEOFF

 

[tenikiwon]

To double check if it was check under the hood and in the drivers door jam. There usually put a sticker. If Ford did it, which I think is the only ones that can.


I would like to know about damage as well, but it sounds like it's MAJOR

 

[Blee1099]

The GEM reprogramming refers to a binding/shudder when turning. I had this done about 2 months ago and since then I have had no problem with any noises when turning.

 

[tenikiwon]

Ah, so in my case I'm going with Shift motor cleaning!

 

[GaryGnu]

Originally posted by Blee1099
The GEM reprogramming refers to a binding/shudder when turning. I had this done about 2 months ago and since then I have had no problem with any noises when turning.

That is EXACTLY what my mechanic told me. Thanks.

 

[alphabets13]

i also have a 96 xlt and my lights blink on the dash too when i put in 4wd. it also clunks occasionally on turns. i think this is common and my 4wd works fine. the blinking lights is probably bs if the 4wd works fine anyway. if your having problems with the 4wd ok, but if your worried b/c of those stupid lights, i wouldn't be.

 

[GaryGnu]

Originally posted by alphabets13
i also have a 96 xlt and my lights blink on the dash too when i put in 4wd. it also clunks occasionally on turns. i think this is common and my 4wd works fine. the blinking lights is probably bs if the 4wd works fine anyway. if your having problems with the 4wd ok, but if your worried b/c of those stupid lights, i wouldn't be.

I didn't have this experience. While my 4WD did work sometimes, it most definitely DID NOT work when those lights were blinking.

BTW, I just got my truck back from the Ford dealer again today. $572 (replaced the other sensor, and serviced the transfer case and rear differencial). Added to what I spent at my mechanic, I'm near $1000 for this repair. Although the whole thing was annoying as hell, it was the first major repair I've had on the truck, and its almost 7 years old. And the problem appears to finally be fixed.

 

[alphabets13]

so the lights don't blink anynore?

 

[GaryGnu]

Originally posted by alphabets13
so the lights don't blink anynore?

No. Several times today, I got the truck up to 50mph in 4WD Auto, and I had no issues with the lights. Prior to today, anytime I got the truck past 40mph, the lights would start blinking, every time.

Honestly, I have to wonder if the whole problem wasn't with the speed sensors. I'll never know because I was at the mercy of the Ford dealer. My mechanic was not as knowledgable about the 4WD system as I hoped he'd be. The 1996 4WD system seems to be different than all the newer ones. I only wish I had the time and the mechanical ability to have been able to check this out for myself. If I had to do it all over again, I would try replacing the sensors on my own as some people here had suggested.

 

[alphabets13]

in my case, it doesn't matter how fast you go but whenever you turn the 4wd on the lights blink. but like i said i'm having no problem with it. i could take it to an electrical place or anywhere that would read the codes for me before i would ever go to ford.