Tcase Woes..plz Help!!

[4x4Hunter]

Alright... I was going to start tearing down the electric motor on the transfer caes, but just prior to doing so, the motor suddenly started working correctly. I decided to leave it be as it was as long as things were good...however later I went to the mall and was testing to make sure it was still working and it cut out on me again. I'm starting to think that there isn't a problem with my motor as much as there might be a bad electrical connection at some point..ANYWAY... I went to Wal Mart to get some ATF fluid for the job that I was going to do, coming out of Wally Mart... I hit the button for the 4x4 and it worked again... again I went through the on/off routine...hitting th button multiple times and each time the mechanism acted as it was designed to do. Does anyone have any ideas? I did do the test on the module in the rear of the truck and the light blinked. What is the standard reaction for that light when there is NO problem with the mechanisms? I can really use some advice at this point... guys if you read this, please respond. As of right now, the mechanism is working as it is designed to do. I'm just worried that it wont keep doing that and I'll end up in a snow storm without my 4x4.

 

[RON COX]

Check out this website Dead Link Removed
Hopefully this will help you. Both my Explorer and Ranger went out the same weekend, it sucks. The Explorers motor was shot and I found one in a wrecking yard for $50. Works like a charm. The Ranger was just gummed up from a plastic piece that had broke off from the stop knob, it's hard to explain the site will explain better. You don't need to remove the balancer or buy any tranny fluid for the job. When you take the motor apart watch out for the small springs for the armatures. Use breadties to hold the armatures in while you put the cover back on. Be careful not to pull the rear cover off the electric motor, this is what broke mine. The spring retainer which holds a brass bushing will not like this. Good luck.

 

[4x4Hunter]

I'm not sure that my problems are the same as those of the tcase electronic shifter.. For instance...right now the problem seems to have cleared up. Would you think it possible that the 4x4 would work occassionally? I've read over that site that you put up. I'm not totally convinced that tearing it apart and cleaning the contacts is the answer I need....I'm considering it, but until i'm sure.... I really dont want to get into that.

 

[RON COX]

My Ranger was intermittent also and it was that piece of plastic that got pulled into the worm gear. This won't allow the full movement. It should only take about an hour to clean it up. Simple had tools is all you need. I was hesitant also at first, but when I found the dealer wanted $400 to fix it I changed my mind. I don't really don't think the t-case shift module is the problem. Hope you find the problem.

 

[Longs]

I also did the transfer case motor rebuild on my '93. Prior to that, I'd have intermittent trouble getting 4x4 to engage, especially if it was cold. When it would engage, sometimes I'd hear the relay in the back passenger compartment click 4-5 times before the dash light finally came on. Since the rebuild, it's one click and the 4x4 engages, as good as new.

If you've removed the two connectors from the left side of the controller as described on Jeff Singleton's page, the LED should flash when you press the white button.

The rubber piece from the stop knob in my motor was also shot - replaced it with a piece of 5/16" fuel line. I took everything apart and cleaned everything thoroughly - make sure you scribe everything before disassembly so that you can get things lined up properly when you reassemble.

 

[4x4Hunter]

Alright, good to hear that the intermittent 4x4 is common. I was afraid that i was getting into something else. That's exactly what my problem is, the 4x4 is more prone to not working when it is especially cold outside... which is everyday around here...And the 4-5 clicks is true as well. I looked at the T case from the rear and it doesnt appear to be the same as the one as on Dr.Bob's page... it looks like i have more stuff on there than that. I'm probably going to get a Chilton's or Hayne's today, anyone have any idea which has better illustrations of that section...and also what tools I will need to do the repair work.

Thanks all!

 

[CHH777]

4x4 "Crap Shoot" button...

I think everyone with the electronic shift BW t-case has/will experience this problem. I even emailed an executive at BW but never got a response.

Mine seems to act up on colder days also. Then once I get it engaged and do some wheeling everything heats up and it won't disengage. AAaaaarrrrghhhhhhhhhhhh!!!

Needless to say this is a piss-poor design that should have been recalled long ago.

 

[4x4Hunter]

hmmm... recall .. good idea... get it replaced for free perhaps? that would be lucky now wouldnt it

 

[RON COX]

I've looked in the Ford service manuals at the library and they don't break down the electric motor. I can't find anything on it. But you really don't need anything like that, it is pretty straight forward.

 

[4x4Hunter]

Alright. Well I have tomorrow scheduled in for repair of the 4x4 electric motor. I went out tonite and tried the 4x4 and nothing again. It only seems to like to work when the weather is warm. Kind of useless considering its generally not WARM when the snow is falling. You'd think that the design of these things would be abit better...ofcourse its nearly 10 years old. I guess I shouldnt complain too much. This is really the first MAJOR repair/fix that I've had beyond the usual auto hub deal.

Thanks everyone for your assistance and help. If there are any ideas to help please let me know what you might be able to offer. I noticed that I have a transfer case damper on mine. The motor that i'm taking apart is located directly above this correct? Will I need to remove the damper prior to removing the electric motor? Any other obstacles in my way? ... Thanks again

 

[Longs]

The information on Jeff Singleton's page (or the Dr. Bob page, whatever you want to call it) is pretty comprehensive. The pictures posted there give you a pretty good exploded view of the motor and position sensors. My experience is there as "J.L.".

Just make sure you pay close attention to the orientation of parts, etc. as you disassemble, and if you have any doubt, mark/scribe assemblies before you take them apart so that you can be sure to line them up exactly as they were.

Good Luck!

 

[BExplorer]

Motor...

I did mine on Christmas eve, for the second time in one month. The first time I cleaned the motor itself and it worked fine. The second time I dismatled the grey plastic thing, it has a disk that has contact on wires to the control module, it was of the shaft, I had to glue it back and know it is working normally. For the last year I was getting intermittent 4x4 too, maybe that disk was on it's way to fall off.