Transfer Case Or Shift Motor?!?!?! HELP....

[ExloringXLT]

4X4 issues

Looking forward to your updates Camellia301 as I have similar problems but not necessarily identical. I just wish I had the patience and awesome attitude you have!

Did you really drive your explorer with the shift motor dangling? Sounds dangerous and down right irresponsible. I will do the same come daylight - hey why not at this point.

When I took off my shift motor, the shaft was pointing to L. (Other markings same as you - L, N, or H) I knew I was locked in 4X4 because of the binding up front (that went away after taking off the front drive line, and returned upon putting it back on). I swore I was stuck in 4 high because I can do 70 mph on the freeway with no shifting issues, not even any vibration. So it has to be releasing at some point - I can only guess.

Question: When you turned the shaft on the transfer case, how hard was it to turn? I used my fingers and it spun easily. However, since it was in the L position, I put the tranny in Neutral since it showed it was locked in L. Not sure if that was prudent or not. Anyone?

The shift motor was also aligned so that I could really only put it back on with the shaft in between the N and the H. I thought I got lucky but no such luck. I still have binding on turns in the front end.

I have a new shift motor, but was unable to install it with having to change the wiring harness - not gonna do that in the dark!

Last question: Does anyone know if its possible, or should be/shouldn't be possible, to turn the inside of shift motor to align with whatever position my transfer case shaft is in? Or is that piece immovable on the shift motor? Can't seem to get the old or new shift motor to budge. I know that's a bass ackwards approach, but hey, it may make things easier.

Oh, and should I leave the tranny in Park (Not neutral) when trying to turn the transfer case shaft? Thanks everyone! I am open to ANY suggestions including the best fire accelerator - if and when it comes to that.

ooops last thing. I truly do not believe unplugging the Transfer case plug from the shift motor, let alone anything brown wire related, can help ion any way when you are already locked up in 4X4. Is that a correct assumption? My lights function normally, I hear the clunk when shifting to 4 low, light shows 4 low, and unlike you Camellia301, no flashing O/D lights. However, that light does come on when I accidentally hit the end of my column shifter - and I'm guessing I'm not the only one! Stupid placement for that button!

 

[snoranger]

ExXLT... You're not going to be able to turn the shift motor by hand. It uses a worm gear, they are a pain in the a$$ to turn by hand from the driven side.

I prefer lighter fluid as an accelerant.

If your case is stuck in 4wd with no power to the brown wire, you have a transfer case issue. Inside the case, the magnet pulls on a plate which jams 3 ball bearings to engage 4wd. I've seen it where one of the bearings jump out of the groove and lock 4wd solid.

 

[Maniak]

Mark, I see you're on too.... care to chime in on my feats for today??

What what you described I'm leaning away from the transfer case or shift motor. From what you have done, and the fact that its sluggish leads me to think its a transmission issue.

The trick will be finding a trans shop that just doesn't say "rebuild" to everything. A good trans shop should be able to read the codes from the trans (I don't know if that is something that you can do.. I know my code readers won't read the trans codes but my neighbors snap on one will).

also, I don't trust junkyard transmission. IF you can find a vehicle that got into an accident you have a better chance of the trans being good (it was driving when wrecked) I just haven't had the best luck with transmission over the years, except for the Ford c6.

~Mark

 

[ExloringXLT]

ExXLT... You're not going to be able to turn the shift motor by hand. It uses a worm gear, they are a pain in the a$$ to turn by hand from the driven side.

I prefer lighter fluid as an accelerant.

If your case is stuck in 4wd with no power to the brown wire, you have a transfer case issue. Inside the case, the magnet pulls on a plate which jams 3 ball bearings to engage 4wd. I've seen it where one of the bearings jump out of the groove and lock 4wd solid.

Thanks snoranger. I'm going to test the brown wire once and for all to see if it is getting power. If it is, I am back to where I started. Ford mechanic said 2nd gen explorers always get locked in 4X4, and the solution is to tap the shift motor to unlock while a helper turns the 4X4 switch thru Auto, 4H, and 4L. I banged on it, but without a helper shifting.

I could always bang the hell out of the transfer case and "pinball" one of the bearings back in place. Yeah, not likely. I don't want to get dirty today so I am going to recheck all the fuses and relays again hoping I missed one. Yeah, not likely.

Does the 99 Explorer XLT have a transfer case relay? I've seen pics online, but not sure if I even have what they are showing:

Here's a pic

Thanks - Mike

 

[snoranger]

The (so called) mechanic is an idiot. On a second gen, the shift motor doesn't control 4wd... Just high and low range. Plus, banging on something isn't a way to fix anything. He must be one if those " if you can't fix it with a hammer, you have an electrical problem" mechanics.

 

[Camellia301]

What what you described I'm leaning away from the transfer case or shift motor. From what you have done, and the fact that its sluggish leads me to think its a transmission issue.

The trick will be finding a trans shop that just doesn't say "rebuild" to everything. A good trans shop should be able to read the codes from the trans (I don't know if that is something that you can do.. I know my code readers won't read the trans codes but my neighbors snap on one will).

also, I don't trust junkyard transmission. IF you can find a vehicle that got into an accident you have a better chance of the trans being good (it was driving when wrecked) I just haven't had the best luck with transmission over the years, except for the Ford c6.

~Mark

Funny you said that Mark because when I went there to pull the relays.... almost all of them were in wrecks but there were about 3 that were in tact as if they just died. So when I get one I will need to deposit money and I will walk around and look at odometers because mine is at 187K and will ask for the one I want... I know it will come with a 30 day and I can return it within that time if it doesn't work.

I have the paper from the read at the ford dealer around here somewhere just have to locate it!

ExXlt.... I didn't mean dangling just resting and duct taped to something else. I just didn't want to put it back on before the test drive... lol

So Guys/Gals a tranny it is!!!

 

[ExloringXLT]

Cam - I just ran across something that probably in no way will help you, but it's free and worth a check?

Symptoms: Erratic shifting and a blinking O/D light are common symptoms.


Solution: Check speed sensor located on rear differential.

You've probably already done this, but I didn't see it in this post.

Please do keep us updated on your progress. It's looking more and more like my Transfer Case is at issue But I will most likely (definitely) waste my time checking other things since I don't want to pay for a new or used case! I suppose I could manage to take the old transfer case off, but have 0 ideas on what to look for once it is off.

Mike

 

[snoranger]

Camellia... I just noticed you're local. If it drives good enough to make it to Perth Amboy, I can check it out for you. (I'm stuck there M-F, 8-4:30.)

 

[Camellia301]

Cam - I just ran across something that probably in no way will help you, but it's free and worth a check?

Symptoms: Erratic shifting and a blinking O/D light are common symptoms.


Solution: Check speed sensor located on rear differential.

You've probably already done this, but I didn't see it in this post.

Please do keep us updated on your progress. It's looking more and more like my Transfer Case is at issue But I will most likely (definitely) waste my time checking other things since I don't want to pay for a new or used case! I suppose I could manage to take the old transfer case off, but have 0 ideas on what to look for once it is off.

Mike

Thanx Mike and I must say.... It's worth a try... watched a video on you tube, junk yard parts are $10-$15 depending and new appx $30... Again, worth a try... I will do it! If that doesn't work I will be paying Snoranger in Perth Amboy a visit via tow truck!
C

 

[Camellia301]

Camellia... I just noticed you're local. If it drives good enough to make it to Perth Amboy, I can check it out for you. (I'm stuck there M-F, 8-4:30.)

Snoranger,
Might have to tow it... my military auto ins tows for free up to 14 miles... but first I will try the junk yard speed sensor suggestion by ExXlt/Mike.. While I'm feeling like a "DIY Diva!" Either way I will indeed pay you a visit.... wanna get it looked at properly before the cold comes!!! Driving it to you is what I'm hoping for with the speed sensor fix..... but again I will tow it if need be! See you soon!
C

 

[ExloringXLT]

ExXLT... You're not going to be able to turn the shift motor by hand. It uses a worm gear, they are a pain in the a$$ to turn by hand from the driven side.

I prefer lighter fluid as an accelerant.

If your case is stuck in 4wd with no power to the brown wire, you have a transfer case issue. Inside the case, the magnet pulls on a plate which jams 3 ball bearings to engage 4wd. I've seen it where one of the bearings jump out of the groove and lock 4wd solid.

3 bearings? Do you think this is one of them?:
Case-Bearing

I most likely need a clutch coil too, but don't think those are replaceable???

 

[snoranger]

3 bearings? Do you think this is one of them?:
Case-Bearing

I most likely need a clutch coil too, but don't think those are replaceable???

Probably not (your link just goes to a search screen). They aren't really "bearings", just three steel balls.

 

[ExloringXLT]

Probably not (your link just goes to a search screen). They aren't really "bearings", just three steel balls.

Hmmm. Now I'm not sure I'm even locked in 4X4. Got stuck trying to turn around on a dirt road yesterday. Stood and watched only one rear tire spin and dig even a deeper hole. Wouldn't both rear tires spin if I was stuck in 4X4? The shift motor was disconnected and the front drive shaft was off and sitting at home. I will put the front drive-line back on to see if it still binds up front which I can guarantee you it will. Does this only one rear wheel spinning add anything to the puzzle? I was in reverse when I dug the hole that got me stuck. In front of me was a tree keeping me from going over a cliff. Thanks...Mike

P.S. Cut my rear seat belt off and used it as a tow strap. A nearby camper pulled me out and it was his idea, not mine. It worked. Now I have a tow strap!