T-Case Motor

[eric4welches]

I too have been dealing with a 4x4 issue on my '92 XLT. Buttons on dash don't work. After reading through the 4x4 Troubleshooting guide, I decided to give it a go and try to "fix" the shift motor. I was able to remove the motor without too much trouble. I ran into the "brown wire" issue. I know how to get passed that but... I could not figure out how to pull the big gear. So I ask...

"How do you remove the big gear from the gear housing" ?

Thanks in advance!

 

[arco777]

Once the gear is exposed, a few soft whacks with a mallet should extract it. First make sure the tiny circlip on the gear shaft/spindle is removed, if present.

 

[eric4welches]

Arco777 - Thanks for the reply.
If the circlip exists, would it be on the on the side of the gear that engages with the shifter on the transfer case?

Thanks

 

[arco777]

It would be holding the gear down into the housing, accessible once you remove the dust cover. I usually just use a small pliers or pair of screwdrivers to pop it off, then a pliers to clip it back on later. Many Ford power window motors have this circlip as well.

 

[IvDogg]

I too have been dealing with a 4x4 issue on my '92 XLT. Buttons on dash don't work. After reading through the 4x4 Troubleshooting guide, I decided to give it a go and try to "fix" the shift motor. I was able to remove the motor without too much trouble. I ran into the "brown wire" issue. I know how to get passed that but... I could not figure out how to pull the big gear. So I ask...

"How do you remove the big gear from the gear housing" ?

Thanks in advance!

Hi, did fixing the motor resolve this issue.

I'm having what sounds like the same issue:

- When I press the 4x4 high button I can hear the relays clicking, but no lights on switch.

- I've tested the 4x4 module and it passed.

- The LED on the 4x4 switch works.

- So I'm fairly certain a T Case motor rebuild/replacement should fix it.

Any thoughts anyone else?