Transfer case trouble?? Might be something different?

[02XLT headache]

Transfer case trouble?? Brown wire thing?

I am a newbie here and I have been looking at the transfer case/4wd questions and problems on here and I have not found my specific problem. So here goes,

I just recently took my 02 XLT V6 to the dealer to get the 4wd fixed. The 4wd auto, high, and low did not work at all. The lights on the dash work properly when you push the buttons but, the 4wd does not engage. In the past I went through the 4wd lights flashing, the lights not coming on, and so on, and they have all been repaired. This problem is different. The dealer replaced the 4wd motor and that still didnt do the trick. Everything still does not work. I have to take it back on tuesday so they can open up the transfer case and have a look to try to figure it out (i have my doubts they will though LOL). Does anyone have any clue of what might be going on?

Thank you in advance for any help with this matter.

 

[IZwack]

some good read:
http://www.explorerforum.com/forums/showthread.php?p=1342405#post1342405

 

[02XLT headache]

I forgot to add, that the dealer said it was working when the vehicle was up on the lift. I was not there to witness this so I am not positive this is the case.

 

[02XLT headache]

I noticed that "dogfriend" posted this in another thread,

The brown wire going into the transfer case supplies the current for the electromagnetic coil which engages the clutch. It uses a PWM (pulse width modulated) signal to vary the amount of time that the clutch engages. If you confirm that the signal is being sent along the brown wire, but your front wheels don't turn when all wheels are in the air, then it sounds like either the coil or the clutch are no longer working.

My wheels aparently do turn when it is on the lift so, what could be some causes? I noticed some folks said they ran a 12v source to a toggle switch to switch on the 4wd but, I would like it to work like it is supposed to so, what may have to be changed?

 

[IZwack]

...My wheels aparently do turn when it is on the lift so, what could be some causes? I noticed some folks said they ran a 12v source to a toggle switch to switch on the 4wd but, I would like it to work like it is supposed to so, what may have to be changed?

The front wheels not turning in the air can still be an electrical or a mechanical problem. Running a 12v source to the brown wire was meant to only narrow down the culprit. Thereofore, it wasn't meant to be a permanent solution.

If the direct 12v source powers the front wheels, then you've narrowed the problem down to someting before the brown wire - either a switch, fuse, etc...

On the other hand, if the 12v source still does not engage the front wheels, then the problem is either the (internal) electromagnetic coil, or its a mechanical problem internal of the transfer case - both of which require the transfer case to be opened.