Hey Guys. New to the forums here and I thought I would see if anyone has encountered my problem yet.

While driving down the road under light loads the 4wd was trying to engage. This happened on and off for about a week. Before this, I could only get the 4w low to engage a few times (now not at all) The last time I had it in 4WD low it took about 30 minutes for me to get it out and back into 2wd. It did fine in 4 high and AWD. Anyway I put it on the list of things to fix and now about a month later the wife is driving it and its locked in 4w low and won't come out. The 4wd switch was never moved. We had to rig a remote switch to the motor on the transfer case to make it wind back out to get home. (This has happened twice)

Ford wants $75 an hour to figure it out. Oh yeah, they have never heard of this problem (I called 3 places) To add to this my friend has a 99 XLT 5.4 and his is doing the exact same thing. To fix his he pulled a couple of fuses. 4WD doesn't work but it doesn't lock in cruising down the road either. Anyone know how to fix this problem? Thanks for any help

 

Welcome to the site!

The 2wd-awd-4hi-4lo selector ****/switch on the dash has a history of failure. I'd start with replacing that (very easy job) and see if the problem continues.

 

Ford also uses a very thin guage wire for this switch. If the panel surrounding the switch was ever pulled off and left to hang by that wire...

 

Thanks for the reply guys. I have heard the switch would go bad but haven't heard that it would cause it to engage the 4wd while driving. I might be able to get one and try it out. I went to the junk yard to try out a new (gem?). It was located behind the dash but, it didn't change a thing. Same problem. What could be telling it to engage if it isn't the gem? Thanks agin for the help.

 

A shorted out switch.

 

Heh heh, okay I try to locate one. Thanks

 

Well I pulled the switch out today and even though I am not an electrical genius nothing appears to be wrong. Nothing I could see was burned. (I know get another switch) While I was at it I tried to engage the 4h&4low. Nothing. All it would do was light up the AWD option but it still wouldn't engage. When I would switch it from 2 to AWD I could hear the solinoid clicking ( I am guessing they are vac operated) The solinoids were located on the passenger side firewall. Any more thoughts? Thanks again.

 

I don't recall anyone ever taking the time or putting in the effort to find out "why" the switches were failing.

When our '97 Expy started experiencing symptoms similar to those you are having, a switch replacement cured the problem. I can't guarantee that your issue will be resolved with a new switch, but it will eliminate a known problem area as being the culprit.

 

You stated that if you remotely wire a switch to the motor it works. I would say your problem isn't the motor, but lack of power to your motor. Check to see that you have voltage going to and from your A4WD switch. If so, check voltage at the shift motor. Use a volt meter, or make your own using a 12V light bulb and wires. Use one to ground and one to probe with. Make sure your ignition switch is on. Take your time and be careful.

Good luck