So, after searching and reading and searching some more... I have to ask for help. I found many threads suggesting different ideas, I have tried all except new parts. Here is my issue, I have ESOF... When I flip the switch to 4x4Hi, it will go into 4x4Hi. When I flip it to 4x4Lo, it goes in. It will not go the other direction. When it is in 4x4Lo, it will not go to 4x4Hi or 2x4. In 4x4Hi it will not go to 2x4, but it will go to 4x4Lo. I have swapped relays, even swapped shift motors off a friend's truck. The only way to get it back to 2x4 is to take the motor off and move it back. Please help! Getting tired of freezing my behind off to save 5mpg... Been off and on troubleshooting for 3 yrs now... finally fed up. Only thing left seems to be a bad wire?

 

Below is a link to another FTE member that had a similar problem as you are having. I cannot offer any further advice other than this.

https://www.ford-trucks.com/forums/1...low-range.html

 

Sous, thanks for the link. After reading that thread, I guess I need to try and swap the GEM, and trace the wiring looking for a bare/burnt wire. Will post when I get it figured out.

 

Let us know what you find.

 

Will do! I understand how frustrating it is when the solution isn't given.

 

the only time I had this issue was when we had a few days of extreme cold, something froze up and would not disengage/ put it in the shop for the night and all was good. does not seem to be your case?

 

Wish that were all it was skip. First time it happened was middle of august couple years ago. Getting ready to tear into it now. Will post what i find

 

On the motor assembly there is a position switch, located on top of the motor, it is held in by 2 tamper proof t20 or t-25 torx, cant remember which one, they go bad alot, first check the connector, should be 3 orange wires, if that gets all crusted up the GEM module doesn't know what range your in and shuts down the 4x4. That's why I prefer the stick through the floor, non of this crap that screws up in the worst possible time. I have found several times that taking that switch out, cleaning the connector and using electrical contact cleaner clean the heck out of the sensor, if yours is sealed some are drill a small 1/8th inch hole stick the spray tube into the sensor and flood it with contact cleaner, let it sit, see how the sensor moves should be smooth but you can feel the contacts. Drain out the cleaner and using a blowgun clean out the rest of the sensor, reassemble say a short prayer and see what you got, if it's all good seal the hole you made with some black RTV. Reset any trouble codes, there will be some and your good to go. HAVE FUN and as a saftey check make sure that harness didn't rub thru the driveshaft coradan joint, it's close right from the factory so double check that. I have repaired about a dozen that way, and still on the road. Hope you have good luck.

 

Good Luck!

 

David, thanks for the tidbit! I will tear it apart and clean it. The dash light comes on when i flip the switch and it does engage 4wd hi from 2wd but not hi from lo. It also goes from 4hi to 4lo but will not go from lo to hi. Would that position switch do that? I ran wires to the motor from the battery and it shifted to 2wd. I also tested power to the relays, I get voltage where expected on the to 4wd switch but nothing when going back. Is this more likely a GEM issue?