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  #1  
Old 05-16-2017, 07:45 PM
Rath Empire Rath Empire is offline
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Default Weird 4x4 issue.

So here's my situation. Transfer case was rebuilt just before winter, put less than 5k miles since then. Transfer case is solid. And 4x4 worked great when I needed it during winter.

Fast forward to a few weeks ago...

When I switch into 4hi the light lights up in the dash, all good there no indication of a problem. Same for 4lo. I can hear it actually moving, so that's good. Problem is no 4x4. Huh? Okay so I take the shift motor off, switch it between the modes with motor off t.case(2w 4hi, 4lo) motor is working, it's rotating etc.

Now, I'm confused as hell. So I put the motor back in, shift it to 4hi, and take the motor off. There's my issue, it's not fully shifting it to 4hi in the transfer case. So the shift motor wasn't fully shifting.

Okay so I replace the shift motor. Brand new one. Same issue......
By the way I can manually shift it with vice grips perfectly fine and it engages great. It's not hard to shift by hand at all so I don't see why the motor is having issues?

What gets me is the dash lights and everything think it's shifted perfectly fine. Normally it wouldn't light up, or would flash or whatever. And the fact it worked great all winter, and works manually, so I know it's not something wrong with the transfer case rebuild.

Any ideas? Is there some sort of shift motor module thing that might be preventing the motor from going all the way?
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  #2  
Old 05-16-2017, 07:48 PM
pearlkid9988 pearlkid9988 is offline
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Default Re: Weird 4x4 issue.

Sounds like the motor may be weak spinning with no load is easy apply the load of moving the tease linkage and it's not strong enough. New parts can be bad. Especially now a days with Chinese made parts. Lowest bidder and what not. If it's moving it may move it enough to trip whatever sensor triggers the light but not fully engaging.

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  #3  
Old 05-16-2017, 08:02 PM
Rath Empire Rath Empire is offline
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Default Re: Weird 4x4 issue.

Just ran out and tested how far the motor shifts when on the tcase, and when it's off hanging free, just to rest that theory, it shifts the same amount regardless.

I don't see how all of a sudden the motor that was fine got weak, and a brand new one would be just as weak. It's got lots of torque in it.

But yeah, it's not moving it enough, but I don't know why... :/ Damn electronics. Need a manual shift lol.
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Old 05-16-2017, 08:26 PM
Rocky Mountain Daniel Rocky Mountain Daniel is offline
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Default Re: Weird 4x4 issue.

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Last edited by Rocky Mountain Daniel; 05-17-2017 at 05:12 PM.
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  #5  
Old 05-16-2017, 08:39 PM
Rath Empire Rath Empire is offline
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Default Re: Weird 4x4 issue.

Yeah that has nothing to do with anything lol
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Old 05-16-2017, 08:52 PM
ford4thot ford4thot is offline
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Default Re: Weird 4x4 issue.

Quote:
Originally Posted by Rath Empire View Post
Yeah that has nothing to do with anything lol
New driveshafts for increased wheel travel bruh, it had everything to do with everything
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Old 05-16-2017, 09:04 PM
Rath Empire Rath Empire is offline
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Default Re: Weird 4x4 issue.

Quote:
Originally Posted by ford4thot View Post
New driveshafts for increased wheel travel bruh, it had everything to do with everything
Increased wheel travel from a custom front driveshaft that doesn't have anything to do with wheel travel haha
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  #8  
Old 05-17-2017, 05:00 AM
Rocky Mountain Daniel Rocky Mountain Daniel is offline
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Default Re: Weird 4x4 issue.

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Last edited by Rocky Mountain Daniel; 05-17-2017 at 05:12 PM.
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  #9  
Old 05-17-2017, 07:16 AM
Rath Empire Rath Empire is offline
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Default Re: Weird 4x4 issue.

Your front driveshaft doesn't move..... It goes from a solid mounted transfer case to a solid mounted diff.....

If your diff is moving up and down when you go over bump you've got major issues.


And I guess you missed the part about manually shifting it and having everything work perfectly.
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  #10  
Old 05-17-2017, 07:42 AM
cowboybilly9mile cowboybilly9mile is offline
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Default Re: Weird 4x4 issue.

a) I would have done the same, gone out there, dropped the motor and verified that it's working and that the Xfer case can be engaged manually. But.....

b) have you very carefully compared the amount of rotation delivered by the motor against the amount of rotation you deliver with the vise grip (and this is what is known to engage the xfer case) to see if the motor is rotating adequately?

c) yes there is a 4X module and if you use FORscan you can pull the propriety (aka, extended) Ford codes, of which the 4X module has some.

Edit: If you post a reply to this, please respond with something like, I know for a fact rather than, I think so, because anything short of verify and proving proper rotation of the input to the xfer case leaves the question in b) unanswered. Thinking DNE knowing.
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Last edited by cowboybilly9mile; 05-17-2017 at 07:55 AM.
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  #11  
Old 05-17-2017, 08:30 AM
Rath Empire Rath Empire is offline
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Default Re: Weird 4x4 issue.

Yes. I made marks on the shift motor when I shifted it to mark where it was in each position. Whether it's on the transfer case or off, it moves the motor the same amount, and it's not all the way. I measured old motor vs new motor, both are exactly the same.

The amount it rotates is about 1/2 to 3/4 of the way it needs to go.
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  #12  
Old 05-17-2017, 10:08 AM
aroundincircles aroundincircles is offline
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Default Re: Weird 4x4 issue.

How does the power travel from the switch to the motor? could it be grounded somewhere? how does the motor know it has turned enough? is it a time thing, and the motor is turning slower than it should, so its thinking it turned long enough time so it stops? is it a sensor thing, and the sensor is somehow thinking it has turned enough? Sorry I don't know enough about it to give more help, but from what I've read, your motor is not turning enough, it thinks it is turning enough. Is there a relay or or some other electrical component between the switch and the motor that could be going bad?

Sorry if my post doesn't help much, I agree on the physical lever, I have an 89 cherokee, and its so satisfying to shift into 4wd, ca-CLUNK, BANG!, and off we go!
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  #13  
Old 05-17-2017, 10:21 AM
Rath Empire Rath Empire is offline
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Default Re: Weird 4x4 issue.

Of I hadn't just had this one rebuilt.i would have just swapped to a manual haha.

Yeah I don't know enough about the electrical system on the 4x4, relay or something could be a cause if there is one.
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  #14  
Old 05-17-2017, 12:53 PM
Rocky Mountain Daniel Rocky Mountain Daniel is offline
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Default

***Removed***
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Go do truck stuff!!!
2004 Ranger XLT Super Cab Short Bed Step Side
Engine: 4.0 Transmission: Manual No Power anything except steering and brakes of course
Custom Tom Wood's solid rear drive shaft
Custom Tom Wood's double helix front drive shaft

Last edited by Rocky Mountain Daniel; 05-17-2017 at 05:13 PM.
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  #15  
Old 05-17-2017, 01:11 PM
ricochet ricochet is offline
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Default Re: Weird 4x4 issue.

I'm not experienced with shift motors whatsover, but looking at photos of it, it seems that there are wires going into the motor and some wires going into the back of the cam/drive that I suspect are the limit sensors. Can you loosen those three screws on the back and rotate that plate a little bit to allow more movement in the rotation?
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