transfer case electrical plug

[reomack]

I am in the process of replacing the transfer case in my 02 4.6. The replacement case electrical plug is not the same as the plug on the original case. There are two fewer wires coming from the plug on the replacement case. I was told it was from an 02. My truck is an early build. Can any one enlighten me about this? Will the replacement case work? Can anyone provide me with a pinout for this connector? I'm a bit anxious about this and don't want to screw it up. Thanks in advance for any help you can provide.

 

[223thecure]

This might help ?

I am in the process of replacing the transfer case in my 02 4.6. The replacement case electrical plug is not the same as the plug on the original case. There are two fewer wires coming from the plug on the replacement case. I was told it was from an 02. My truck is an early build. Can any one enlighten me about this? Will the replacement case work? Can anyone provide me with a pinout for this connector? I'm a bit anxious about this and don't want to screw it up. Thanks in advance for any help you can provide.

I just checked my RH drive 03 XLT 4.6, as I have the transfer case out of the vehicle & it has a 15pin plug.

Checking the wiring diagrams I have it appears early 4WD WITHOUT traction control have a front & a Rear speed sensor & associated circuits that the later models WITH Traction Control DO NOT have ! They have a 9x pin plug due to no circuits for the speed sensors I imagine.

NO Traction Control diagram

WITH Traction Control

Maybe it is as simple as fitting the speed sensors from old transfer case to new transfer case + swapping over the harness on the transfer case too ???

This could possibly be done if there is actually provisions on the replacement transfer case for the old speed sensors ... and that there actually is the required shutter wheel inside that the sensor reads ???

Is worth investigating anyway ?

 

[reomack]

Physical differences

Just so I am clear about this, does anyone know if there any actual physical differences between the two cases, so that if I swap the shift motor and wiring from the original case to the replacement it will work properly? Also you refer to the speed sensors on the two cases. Are you referring to the small sensor which has wires leading to it from the connector? The orig case has this feature but the replacement case has a single wire going to the ?sensor. More info, the replacement case has nine pins in the plug and the orig has fifteen pins. Also, I do not have any speed sensors on the rear wheels so I don't think the truck is equipped with traction control. I am so confused!!!! I thought this would be a simple swap type R&R, NOT. Thanks in advance for any input/help.

 

[223thecure]

Are you referring to the small sensor which has wires leading to it from the connector? The orig case has this feature but the replacement case has a single wire going to the ?sensor. More info, the replacement case has nine pins in the plug and the orig has fifteen pins. .

YES ... I was refering to the Front Output Shaft Sensor located behind the shift motor ...

And the Rear Output Shaft Sensor located under the rear output shaft ...

I'd imagine if both the transfer cases you have in front of you are physically the same then swapping over the ancillary components (shift motor, sensors & harness) from your old unit onto the replacement has a high degree of probability of success provided that where the sensors are 'sensing' ... that the appropriate shutter wheel is indeed on the shafts inside ?

Hope this helps ?

 

[reomack]

Screwed

On further investigation I have discovered that the two cases are not physically identical. The replacemant not have a front output shaft sensor. Cursory examination was not sufficient to see this at the wrecking yard. I guess I am screwed and will have to find a second replacement. I am left wondering exactly what case I have. I was told it came from an 02 Explorer and took it a bit on faith that it would be a direct replacement. Do you happen to know if I can salvage the situation without buying a second replacement.

 

[223thecure]

Okay ... so if you really are stuck with this other transfer case & can't return it ... If it were me, I'd be seeing if I could remove the rear cover off the replacement transfer case & swap it with the rear case from your original transfer case ... provided it phyically fits & that the 'shutter wheel' that the sensors read actually exists on both the front output & rear output shafts of the replacement one ... it may just be a bolt in solution ???

Worth a look I would imagine ?

 

[223thecure]

Here are the exploded views of the transfer case + parts listing so you can see what I mean from my previous suggestion ...