How to: Rebuild 4X4 Shift Motor

[DeRocha]

Well im not sure if the previous owner did that or not but its definetly sealed, but like I said I tried everything as far as cleaning everything an still didnt work, when it started not working the lights on the 4 wheel drive switches were flashing an they would go out an they would come back on every once in awhile an start flashing some more an then one day the lights wouldnt flicker or nothing, anyone have any ideas? Could it be the computer or switches or relays? Anyone know if there is a way to test these? I heard you can bench test the motor itself by hooking up straight 12v to the yellow an orange wires goin to the motor, is that true?

I have no idea about flashing 4x4 buttons as I have never heard of them flashing. Do you have a picture of them?

It is semi-true you can hook 12v to the electric motor wires.. Semi as in the geared sensor shaft only has a 240 degree movement before it binds. At which point you'd need to reverse polarity to cause the motor to run in reverse.

 

[raceman]

No no pictures, they are the same as in any 1st gen. explorer or ranger cuz if im not mistaken 2nd generation has a knob switch, these are just buttons on the dash above the radio with 2 l.e.d lights on the left side of them to indicate if you are in 4 wheel drive

 

[upnorf]

another hijacker

hey guys, first time user! been looking at this thread cause I was haveing problems with the ol 4x, anyway I just installed manual hubs and went to turn the 4 on and a few clicks and nothin, no light notta, the dash lights come on when I do a start up but not when I turn the knob, so I pull the t case shift motor off hook it up dirctly to voltage and turns, reverse voltage and turns back. I know its been covered in here but I cant find it, does this mean my shift motor is o.k.? anyway , looked tyo see if I could find the module, again - I know its been covered in here but I have dial up and its painfull to do to many searches, its a standard cab 95 xlt 4.0. anyway cant find the module! its not behind the seat! anyway I know I'll get it figured out but just wonderin if someone could give me a hand, thanks and again HI

 

[murrayexplorer]

And to think I almost went out and bought another shift motor. No money spent, just a few hours of my time. Very accurate instructions and oh so helpful. Thanks!

 

[upnorf]

hey raceman, I finally disasembled my shift motor and it has the same sealed unit like in the pic., I tore the rest of it apart cleaned it up a bit put a new piece of hose on the screw and put it back on the truck, turned it on and both 4x light turned on but couldnt get them to turn off! so took it back off the truck and the t-case was still in 2wd!!??? made sure everything was ligned up again put it back on and nothing, had it off and on 3 times now and cant get nothing!, Im wonderin if the sealed unit is toast! did you get yours figured out yet?

 

[raceman]

No I never figured mine out, still pondering about it, yet after I messed with it the first time I never really messed around with it again, im guessing that whatever is in the sealed unit is screwed up

 

[upnorf]

thanks

yea, I think I'm buying a new one! no way to fix the sealed unit part. u can get a new one for about 110.00 thanks for the reply

 

[raceman]

Ya but the weird thing is that mine is a 94 an it shouldnt have the sealed unit in it so im guessing the guy who owned it before must of had trouble with it and replaced it so before I go buy a new one I think im just gonna look around for a decent used transfer case that has the manual shift so theres no more worries with these electronic shifters although they are nice but they just arent reliable.

Also I remember when I pulled mine apart, I looked for the screw that has that bushing on it and on the gear there was 2 holes in it if I remember correctly but no screw, and I looked at the holes an they werent threaded so if possible could you take yours apart again an take some pictures. I figured there must be a sensor inside the sealed unit that tells it how far it has shifted but if yours has the screw on it then maybe that could be the problem with mine but yet when I took it apart there was no screw inside the case or no sign of there being one.

 

[upnorf]

yea mine had the screw and bushing just exactly like in previous pics, but everything above that was sealed! I put it back on for now just so I can drive it around, when I get the new one I'll get some pics of it!

 

[raceman]

Ya if you could do that, that would be great

 

[IHateFordsHelp!]

Help!!!!!!!!!!

ok i've read all of this and a few other threads and heres the deal.
my trucks push button light indicator shows the 4wd is engaged but its not.
i press the switch, back up, but the light stays on.-still not in 4wd.
i have taken apart the electric motor and the little rubber (trojan?) was in peices all dried up.
i replaced this with a small rubber peice of almost the exact same thickness, cleaned everything, put it back together, put it on the transfer case, reassembled everything, but the light is still on--i do hear the controller clicking in the back though when i push the switch, but still no 4wd.
Any ideas what to try next??????????Anyone????????
i'll try anything at this point.

i bought this truck used for $1000.00.
i have changed the plugs, wires, fuel pressure regulator, front brakes, front shocks and now am working on getting the 4wd working......then to move on to the radius arm bushings and alignment, then it will be all done but the body rust!!!

please e-mail me with any suggestions or post it here i will be checking back at least 4 times a day for answers.

thanks to anyone who helps, i have really found this site helpful so far and look foward to you guy's response.

 

[Tbars4]

...do you have auto hubs??? this could be a problem also...have you put it in neutral and pushed the 4wd low button after you had initially gotten the 4wd lite???

 

[IHateFordsHelp!]

Help!!

yes auto hubs
ihave tried the 4wd low button too, it glows while i push it and i hear a click from the back but nothing changes

 

[IHateFordsHelp!]

r u there?

 

[DeRocha]

The good news is the 4x4 button appears to work correctly as it sends an electric pulse to the 4x4 computer in the back (and you have confirmed you hear the relays clicking). The bad news is that both the 4x4 button AND dash "4x4" indicator lights must be illuminated to indicate the shift motor correctly shifted the T-case selector shaft into 4x4. It is common issue for a stray voltage to appear from time to time on the 4x4 dash button (partially illuminating it), but never the 4x4 dash indicator light. Have you used a continuity or electronic multi tester to confirm the shift motor cover is correctly aligned?

When my shift motor was broken I replaced the busted plastic stop bushing, but it still didn't work (pressing 4x4 just caused the relays to click in the 4x4 controller). I solved the problem by using a continuity tester and slightly rotating the sensor cover until all the appropriate wires tested correctly for 2H).

 

[IHateFordsHelp!]

Thanks!!!!!!

Hello and thanks for the replys.

I took the motor back off today and tested it with the battery, it turns!!!
So, now that i knew the motor worked (thanks to this thread!) i tried this.....

I turned the transfer case to 4wH (which is what the push button was indicating) than set the motor to that position and reinstalled it.

when i started up the truck the push button light was bright instead of faded, so i put it in newtral<--god i cannot spell, and pushed the 4wL button
IT WORKED!!!!!!!!!!!!!!!!!!!!!!!!

So i backed it off the ramps, turned off the 4wd (that worked too, went down the road and tried it again in 4WH and 4WL and they both worked!!!!!

Thanks alot again for all the info and i will be recommending this site to some of my buddies at work who have fords.

This site is awesome!!!!!!!

 

[UncleVern]

Thanks!

After getting the bums rush buying my 91 XLT 4WD from a student for $500 I discovered that the 4WD didn't work as reported. Having only 10 days to transfer the title and no $$$ to get it looked at I took a chance and for the most part followed the instructions posted here.

As it turns out, every ape with a tool had been "fixing" the poor thing, I found a spare 4WD computer and most of the missing interior parts stashed with in the panel the one that was hooked up. wiring harness a mess, lights not working... Baby been trashed.

Note: I just slipped the large gear back into position with the shift motor loosly re-mounted on the transfer case, therfore timed correctly. I am grinnin, the thang actually works and I am ready to fight ice and mud up in the cascade wilderness.

Thanks for the tip on the wire ties, I thought an old fart like me knew all the tricks.

Lots more to fix on this rig, I'll wander back and thanks again!

VernC

 

[MooseCat]

Torx bit problem

Having trouble fitting the torx bit into the bolt head. The center piece is in the way. Should I have a hollow bit?

 

[Maniak]

If your saying there is a pin in the middle of the torx hole on the bolt then yes.. you need a security torx bit. They have a hole in the center for the pin.

~Mark

 

[MooseCat]

No shift motor?

Is it safe to run with the shift motor completely off? I'm one of those idiots who dove in without reading the whole post. TSK TSK!! Thanks for the great article though.