Problems with 4wd engaging

[boostranger]

91 XLT auto with push button and manual hubs.

Sometimes it works fine, other times nothing, and sometimes the light next to 4hi will light for a couple seconds and ou will hear relays clicking then the light goes off and no 4wd. Sometimes 4hi will work fine but 4low will not shift.

I finally got around to pulling apart the shift motor as that seems to be the most common problem, and i must say for haveing just shy of 200k it looked like brand new inside that caseing. not a spec of rust or dirt on any of the windings, brushes looked good, springs were in place.

I am at a loss, gona grab a switch next time at the yard and see if it helps, would apreciate any suggestions.

Thanx
Jon

 

[Kirby N.]

Sandpaper the area where the brushes make contact. There is a load of info on cleaning the shift motors on this site and therangerstation.com. I did it to 3 motors that shifted sparatically and it fixed them.

 

[EMG7895]

What I did is get some oil and hook up the motor to 12v without the gear in place and i cycled it back and forth to get the oil to free things up.

 

[boostranger]

hmm .. i guess i will have to pull it apart again .... it looked like brand new inside, not like most used electric motors i have ever seen .. no corrosion, rust, sand, or discoloration.

Thanx
Jon

 

[leenjen]

did you figure it out?

i'm having a similar problem with my 4wd and would like any suggestions.

my 4x4 and 4 low buttons dont even light up anymore.

 

[Kirby N.]

do a search on cleaning them. I did it to three of them and fixed them all- or you can go to ford and buy a $300 shift motor to fix it.

 

[xplor_off-road]

i had just about the same prob. a couple weeks ago and found the 4wd fuse had some corrosion, i replaced the fuse and started working fine