T-case Motor Too Tight?

[93_Exploder]

I tried searching but was unsuccesfull in choosing the correct keywords to use so if there is a post that would be helpfull, please post a link.

1993 Explorer 4.0
Push button 4x4
Automatic trans and hubs

I recently purchased a remanufactured T-case motor and when all 4 bolts/screws are tightened, the 4x4 won't engage. The unit in the back just makes a series of clicks. Now when I remove a couple of the screws around the, umm, part that turns the T-case shaft, it works 90% of the time. I'm trying to get it up to 100% right now and I tried putting a washer between the T-case and the motor at all 4 bolts and it seemed to work really good. My concern is around the shaft part though. Should I just use a gasket maker, adhesive backed gasket material, an o-ring, ect, to try and seal out the elements. Or is there something I should/need to do that I just don't know about.

Thank you

 

[DeRocha]

I haven't heard of this issue with the shift motor before.. Most shift motor issues are caused by 1) broken T-case selector shaft bump stop (which allows the sensor to move slightly outside of its operating range). 2) Bound motor causing an increased AMP draw. But I'm wondering if loosening the bolts allows the whole assembly to slightly move left/right (not in out) which allows the T-Case sensor to make intermittent contact..
After I rebuilt my shift motor a few years back I pressed the 4x4 button all I heard were the 4x4 relays on the 4x4 controller clicking away... Basically the sensor cover needed to be slightly turned 1/8"+ (one direction or the other) so that the fingers on the cover would correctly align with the metalic sensor plate on the T-Case. Once continuity was re-aquired it was good to go... Anyway for a more detailed explaination and pics check out the Shift motor rebuild thread.

 

[EMG7895]

Look at the rebuild thread and mark the cover then take it off and remove the big gear. Then remount the motor on the tcase and put the gear back in on the shaft and use the marks to put the cover back on.

 

[93_Exploder]

Is doing that going to be hard? I've done some mechanical work before but never something like this. Later today I'll check it out and see what I can do. Besides that, is there anything else I might be able to do?

 

[DeRocha]

There really isn't anything you could do besides getting a multi-meter and testing the shift motor's wiring harness for the correct continuity between the pins (see explorer maint link below for shift motor continuity test).

Anyway it is a piece of cake to remove the cover and re-align it. You just need to get security torx bits to remove the cover (Sears etc.). These bits are used elsewhere (ex. MAF) on your X...