Used t-case - cost?

[gmanpaint]

That case had the brown wire cut, make sure you have a good connection to it.

Check the sensors from your shift motor. Make sure they are in the proper holes in the t-case, and they are not cracked or have broken wires.

If your O/D was flashing for 5 yrs, I cant even think to how it drove all that time. I would check the trans codes.

Your 4x4 module or GEM might have an issue as well.

This is all I can think of right now. Sorry it didn't go smooth for you.

 

[Paraphoe]

That case had the brown wire cut, make sure you have a good connection to it.

Got that covered. Buddy is certified with all that electric stuff.

Check the sensors from your shift motor. Make sure they are in the proper holes in the t-case, and they are not cracked or have broken wires.

They looked fine to me. Put them in the holes I took them out of, wires were OK, all seemed well.. What exactly do these sense?

If your O/D was flashing for 5 yrs, I cant even think to how it drove all that time. I would check the trans codes.

No mechanic has been able to pull a code. It started after my father got the transmission rebuilt in 04 before I bought it. Brought it back to the guy after with the light going and he couldn't find the problem and because it ran fine we kinda just went with it.

Your 4x4 module or GEM might have an issue as well.

Time to do a search on that......

This is all I can think of right now. Sorry it didn't go smooth for you.

Well, at least the popping is gone...hah.

 

[Paraphoe]

http://www.explorerforum.com/forums/showpost.php?p=1501052&postcount=4

I found that post which seems to point to the GEM by connecting the fact that my passenger window won't roll down with the flashing 4wd lights. Very interesting, as I wouldn't have even remotely considered the fact that those issues are related. Could the GEM be causing the truck to be stuck in 4wd?

 

[IZwack]

If you were able to get the t-case back into the 4H position (as marked on the t-case under the shift motor), then just disconnect the electrical connector and the binding should be gone. Then the problem is electrical.

For the future, try not to use 4LO. 4LO will not help you unless you have absolute grip (rocks). Stay in 4H or Auto mode as 4LO is a mechanical change - a change which sometimes can not be undone rendering the vehicle stuck in LO range.

 

[Paraphoe]

If you were able to get the t-case back into the 4H position (as marked on the t-case under the shift motor), then just disconnect the electrical connector and the binding should be gone. Then the problem is electrical.

OK...that's what was suggested when I searched. If I unplug this, I'm then 2wd? The 4wd lights will be flashing, but without consequence, correct?

 

[IZwack]

OK...that's what was suggested when I searched. If I unplug this, I'm then 2wd? The 4wd lights will be flashing, but without consequence, correct?

According to a test Glacier did, the transmission feeds off of the VSS signal on the tailshaft housing - so I think the transmission wont shift correctly. Unplugging the connector is for diagnosis only.

 

[Paraphoe]

OK....I just unplugged the connector. It SEEMS like it's not in 4wd because it's not really binding in tight turns. I will have to get it up on jacks as soon as I can to verify for sure.

 

[IZwack]

If you can make tight turns w/o popping, slipping tires, or engine dying, then thats a good enough test. So you probably dont need to put it up on jackstands.

So the problem is probably electrical.

 

[gmanpaint]

Have you tried to disconnect the battery to reset the computer?

 

[storlied]

Try swapping your GEM.. after you reset the computer like gmanpaint just said. It can't hurt.. I really think it's your GEM.

 

[dogfriend]

Could the GEM be causing the truck to be stuck in 4wd?

Possible. The GEM controls when to engage 4wd by sending a PWM signal on the yellow wire to the TOD relay which then sends a larger current signal on the infamous brown wire. If the GEM is fubar, then its possible it is causing it to be in 4wd.

The GEM also controls and reads the shift motor position. The GEM looks at the position of the 4wd switch (the one that says Auto, 4Hi, 4Low) by reading the resistance. If you switch to 4Low, it activates the shift motor to change to 4Low. It also reads a series of plates inside the shift motor to determine its position. If the position doesn't match the selection of the 4wd switch, then it flashes the 4wd lights to let you know something is wrong. There are other issues that could cause the flashing lights as well, such as a problem with one of the speed sensors.

 

[Paraphoe]

OK. I confirmed that unplugging the connector to the shift motor/case disables 4 wheel drive. So it's definitely, like IZ said, narrowed down to an electrical issue and not a mechanical one. I also pulled and checked every single fuse in the box. All are good. I then unplugged the battery and let the truck sit for 20 minutes, just in case. No change. There is still no communication between the whatever controls the 4wd engaging, an 4wd switch, and the shift motor.

I'm also not certain it's the GEM anymore because the window that wouldn't go down is now functioning properly, along with all the other windows, door locks, etc.

Any other steps I can take to try to narrow this down? Get a new speed sensor? New shift motor entirely?

 

[Turdle]

Is there a 4wd module like 1st gen has, in the 2nd gens?

I am referring to the 4wd relay box in the driver side rear panel

 

[dogfriend]

Is there a 4wd module like 1st gen has, in the 2nd gens?

Yes, there is a module that is basically 2 relays and a diode. It is controlled by the GEM to make the shift from L to H and H to L. It is supposed to be near the GEM according to the EVTM.

 

[storlied]

...lmao.. I thought that Was the GEM... That's what I've been refering to this whole time.. that box in the jack storage compartment where Turdle mentioned... it's above the wheel well

 

[CASTLE95X]

Hey ya'll i'm a new member but i've been studying for a while since i got my 95 ex. Anyway, paraphoe, when you disconnected the battery did you touch the neg and pos together to reset the 'puter? I did it when i cleaned my maf and my rig ran fine but it got dirty again so she runs like poo.

 

[Paraphoe]

Yes, there is a module that is basically 2 relays and a diode. It is controlled by the GEM to make the shift from L to H and H to L. It is supposed to be near the GEM according to the EVTM.

OK, but if all this does is switch from high to low and low to high, it can't be causing the truck to stay stuck in high, right? What communicates the switch from auto to high and back?

 

[storlied]

Hey ya'll i'm a new member but i've been studying for a while since i got my 95 ex. Anyway, paraphoe, when you disconnected the battery did you touch the neg and pos together to reset the 'puter? I did it when i cleaned my maf and my rig ran fine but it got dirty again so she runs like poo.

Don't do that, you're gonna fry something. To reset the computer just disconnect the negative for a minute or so, let the remaining energy ground itself out through the proper grounds.

 

[dogfriend]

OK, but if all this does is switch from high to low and low to high, it can't be causing the truck to stay stuck in high, right? What communicates the switch from auto to high and back?

The GEM. The GEM sends a signal to the TOD relay, the TOD relay sends current on the brown wire to engage the electromagnetic clutch in the transfer case which causes the front driveshaft to engage. Its kinda a Rube Goldberg thing. :

So if it is always getting a signal to engage the clutch, it could be the GEM, it could be the TOD (torque on demand) relay. The TOD relay is a solid state relay; it is possible for it to fail in a way where it always sends current.

 

[V8BoatBuilder]

Jason: If you remove the shift motor from the back of the t-case, but leave it connected electrically, will the motor turn when you shift between H and L?

The motor shifts the case into and out of low gear, it does not hold the case into high or low. If you are in low, and unplug the motor, the case will stay in low (and vise-versa). You can also remove the motor and shift the case manually.

In addition to the GEM, there is a shift motor relay behind the dash which has a higher probability of going bad than the GEM itself.

Flashing 4wd lights could just mean dirty speed sensors (just remove, clean, re-insert) - I've dealt with that problem several times. How many times are they flashing? The speed sensor code is six flashes.

Let me know if you need a hand with a multimeter and or the Ford electrical schematics, electrical systems are my specialty - I'll be in PA (west of Philly) this weekend.