2000 F250SD 4x4 not engaging

[jaitken]

Howdy folks, I've got a 2000 F250SD with what sounds like a fairly common problem: the 4x4 won't engage. With hubs set to "Auto", turn ESOF knob from 2H to 4H, nothing. No clicks, clunks, or dashboard indicator light. Same thing with hubs manually locked in place. Doesn't seem like this is a hub issue this time. Took it to the dealer since I just recently had the Digital Transmission Range Sensor replaced and wondered if maybe there was a connection. They tell me that no, it's the transfer case shift motor and they want roughly $850 to replace it. Ouch. So I told 'em to hold off for now because I wanted to see if this was something I could tackle myself. The tech noted two things. First was that there was power at the motor, so presumably that means that it's not wiring/fuse/etc. Second was code P1864, which appears to be: P1864 Transmission transfer case contact plate power short circuit to battery I'm assuming that the symptoms plus that code are enough to confirm that the motor is indeed shot? Also, I'm not a mechanic but am generally pretty handy. Any reason I can't handle this replacement myself? Looks like I can pick up a replacement motor for under $200, and from what I've read it simply bolts on to the side of the t case. I haven't been under the truck yet but it seems like it ought to be fairly simple: unplug and remove the old motor, install the new one and reconnect it. I'm sure it won't turn out to be that easy of course. :-) If anyone who has done this has comments that'd be great. Thanks for all the help -- this forum has already helped me figure out another issue (failing power door locks), you guys rock!

[Krewat]

That P1864 would mean the switch on the transfer case servo is either bad, or the wiring is pinched somewhere. That "encoder" would normally be changed with the servo motor, so that's a good thing.

One of our sponsors, rockauto.com, has the motor with encoder/switch for $133.79, from Dorman. More Information for DORMAN 600805

If you go to rockauto.com, and drill down to your Ford/2000/F-250/Engine, you'll see this Dorman part, which is brand-new, and a rebuilt Cardone, or a RETECH (never heard of them). I'd go for the new Dorman, if it were me.

You might want to check NAPA or any other auto parts store near you, that way if you get the wrong part (unlikely) then it's easy to return or warranty.

You can definitely handle this replacement if you can unplug two connectors and undo a few bolts (three). It's not even going to leak any fluid

[dmodracer3]

I just had the same problem.. the 4x4 wouldnt do nothing. No lights, wouldnt engage or anyhting. I got a code to that said low battery voltage. Anyway I went through and replaced the computer in the truck, the 4x4 module was bad, and I replaced that. Still nothing. I had power going to the shift motor. I did a couple tests of the GEM module with 2 wires. Everything operates by ground. When I ground each of these wires seperatly one i supposed to engage it in 4x4 high and the other supposed to engage it in 4x4 low. When I did that the shift motor ran but wasnt egaging the transfer case. It turns out I took the shift motor off and took the gear box apart, the small gear on the end of the shift motor was broke. I couldnt just by the small gear I had to buy the whole motor. But it worked.

I figured out. When the shift motor turns it turns another gear thats goes over the shaft the the transfer case. There is all a switch that turns with the transfer case to tell the truck if its in 4x4 or 4x4 low. Since that small gear was broke for one it wouldnt shift into 4x4 but also the lights wouldnt come on. And that caused for those codes to come up. Hope this may help. I have my old 4x4 shift motor I will sell since I had to buy complete new motor and gear box.