New to forum here have a 99 exp A4WD and this problem may only pertain to the awd truck. Under hard acceleration I get a bump/ thud up front like the axle is about to fall out, could be the awd trying to lock in or out not sure, now if I switch to 4whi or 4w low it does not make the noise, I then pulled the 4wd fuse #104 out and no banging, but I assume it os no longer awd, So my question, is there a sensor or something that tells the front diff when to engage/disengage, from my testing it is an electrical or sensor problem anyone ever had this problem or know the fix.
thanks

 

update 1 week later, Fuse #104 is still out no issues, still searching to find the sensor or sensors that may create this problem, is there a drive shaft speed sensor? any one had this issue and resolved it, read up some and everyone has a diff answer. thanks

 

Look for the sensors on the front and rear of the transfer case.

 

I'm down to 2 possible problems Transfer case shift motor and sensor or the GEM module, Will do some more checking today hav e heard alot about GEM mods getting wet from leaky windshield seals and corrosion casing issues, I know it is electrical for sure, looks like the sensor on the shift control motor has quite a few wires that possibly read drive shaft revolutions etc, total new motor and sensor only $65 easy install. Used Gem mods $65 and up one thing I did find out that may or may not be related is but
Gem modules are responsible for the following functions:

• Warning chimes and warning lamps
• One-touch down driver’s side window
• Daytime Running Lamps
• Heated rear window
• Windshield washers and wipers
• Battery saver
• Remote keyless entry
• Illuminated entry with remote keyless entry
• Interior lighting
• Perimeter anti-theft
• Four-wheel drive

My one touch window down function is inop this may be a clue to a damaged GEM...

just a thought



I'm assuming your 4WD isn't working, and that the 4x4 light on the dash is not coming on when you switch the switch to 4WD.

First thing to do is to check the make sure the 4x4 light is working. It should come on briefly when you start the truck. If it does then you know the light is working at least.

Find and check fuse #19, 27, 31, 33, 34, 45 and 111. Don't just visually inspect them, take them out and check them for continuity between the pins with a meter.

Get an assistant, get under the truck with a standard test light and find the 2 pin connector to the transfer case shift motor. Unplug that connector and connect the test light between the two pins of the connector. With the key in the RUN position (the engine doesn't actually have to be running), have your assistant turn the **** to 4WD. The test light should flash a number of times as the 4WD module tries to engage the shift motor.

IF the light flashes, then everything upstream of the shift motor is working. Inspect the connector, and the plug on the shift motor it connects to for any sort of corrosion or indication that there might be a bad connection. If everything looks good the shift motor is probably bad and needs replaced.

If the light does not flash then you need to find out why. The next most likely problem is one of the transfer case shift relays. The shift relays will be in a auxiliary relay box under the hood, drivers side towards the rear of the vehicle. They are usually in a relay box by themselves. Two identical relays with nothing else in the box. The box is wrapped from the factory with fabric electrical tape, but that might be gone if someone has already opened it. First thing to do is remove the relays and look for corrosion. If you find corrosion, clean it up good and try again. If that doesn't work, continue to the next step.

A good test of the relays is two remove them and swap their positions. One of the relays is used to turn the shift motor from the 2WD position, to the 4WD position, and then to the 4Low position. The other relay turns the motor back the opposite direction, from 4Low, back to 4WD, then back to 2WD.

When the relays are swapped, try shifting into 4WD again. If it works, you've found a bad relay and should probably just change them both.

If none of this works, then we'll need to look at the relay base wiring for corrosion and possibly move on to the 4WD control module.

 

http://www.ebay.com/itm/1999-99-FORD-EXPEDITION-NAVIGATOR-4X4-GEM-MODULE-XL14-14B205-AA-/350711016452?pt=Motors_Car_Truck_Parts_Accessories&fits=Model%3AExpedition&hash=item51a8016c04&vxp=mtr

 

After doing some research on this issue I found this TSB..





<table border="0"><tbody><tr><td width="230">FORD:</td><td>1999 F-250 LD
1999-2001 EXPEDITION, F-150</td></tr><tr><td width="230">LINCOLN:</td><td>1999-2001 NAVIGATOR</td></tr></tbody></table>ISSUE:

Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor.
ACTION:

Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details.
SERVICE PROCEDURE

For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case, refer to Section 308-07 of the appropriate model year Workshop Manual.
<table border="0"><tbody><tr><td width="80">NOTE:</td><td>ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. </td></tr></tbody></table><table border="0"><tbody><tr><td width="80">NOTE:</td><td>TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WDS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. </td></tr></tbody></table><table border="0"><tbody><tr><td width="80">NOTE:</td><td>AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. </td></tr></tbody></table><table border="0"><tbody><tr><td width="80">NOTE:</td><td>CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0.</td></tr></tbody></table>UNCOMMANDED SHIFT TO 4L

1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include:
   • Front end binding or hopping while turning
   • Bind feel in drivetrain when backing up and/or turning
   • Audible clunking or grinding noises, and/or
   • Amber low range light illuminated
   1. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM.
   2. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes.
   3. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch ****. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions.
   4. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98.
   5. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition.
2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include:
   • Rapid deceleration
   • High engine revving possibly accompanied by a P1270 DTC in the PCM
   • Clunk/grind noise
   • Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on.
   1. Monitor contact plate A,B,C,D PIDS. With Mode Switch in;
      • A4WD, plate PIDS should read "OCOO"
      • 4H PIDS should read "COOC"
      • 4L PIDS should read "COCO" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary.
   2. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present.

UNCOMMANDED SHIFT TO 4H

1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD.
2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors.
   1. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4" among all four tires, and front and rear axle gear ratio's for matching. <table border="0"><tbody><tr><td width="80">NOTE:</td><td>DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. </td></tr></tbody></table>
   2. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary.
   3. During sensor installation use lubricant on sensor O-ring and verify fully seated before tightening hold-down bracket.
   4. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph).
3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H.
   1. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself.
   2. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition.

STUCK IN 4L AT ALL TIMES

1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address:
   1. Replace the GEM module.
   2. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair.
   3. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition.

<table border="1" cellpadding="3" cellspacing="0"><tbody><tr><th align="center">PART NUMBER</th><th align="center">PART NAME</th></tr><tr><td align="left">YL1Z-7G360-AA</td><td align="left">Shift Motor - Transfer Case (ESOF)</td></tr></tbody></table>

 

Ok here is an update, had some issues on my 99 exy awd.

so far have done all these fixes and all good all cost 0$$$ just some tinker time.

1.Removed GEM opened cover removed PC board the only problem with these are poor solder on many resistors, resolder all resistors now all power accys work perfect locks windows etc. gem cost $350 to buy fox it yourself for free!!
2. 4WD HI LOW not engaging or NO 4x4 LITE coming on.. Transfer case ****s motor removed it 4 bolts, unplug unit take 3 screws out of motor cover remove winding and brushes clean it up good with a little sand paper grease shaft reassemble ( be sure to seal it with atv mine was rusty and had water inside at one time) all shifting back to normal works great $70 savings here.
3. odometer light not working removed cluster resolder pins and resistors on circuit board. works like new. $200 savings.
4. last problem still not solved have clunking noise up front when accelerating hard from stop or roll, in AWD mode removed 4wd fuse under hood problem goes away, no clunking so for sure it is electrical.
Hunting for some type of sensor that possibly measures driveline speed. Anyone else that may have this problem and has AWD pull the 4wd fuse and see if clunking goes away.

 

Are the tires worn evenly and inflated to spec?? Worn tires on one axle and new tires on the other axle will cause the problem you are having. The tires have to have the same circumference within 1/4" or it can cause a problem.

 

all 4 tires are the same and brand new

 

Check the front drive shaft u-joints for wear.