Hey there--

We have a 2000 F250 7.3L Diesel. A few years ago we switched out the auto hubs for manual Warn hubs. We've had no problems with 4x4 since that time, until now!! The 4x4 Hi light is on and the transfer case is engaged. Since the hubs are manual we have them unlocked, however we can't get the 4x4 to disengage. At one point, tried changing to low and it hesitated but finally went in to 4 Lo, then we had a hard time getting it out of 4Lo and back to 4 Hi. Here's what we've tried--checked fuses, checked and replaced relays, checked wiring connection at the transfer case. Husband used volt meter to test power at transfer case wiring connector--showed 0.5 volt of power with the key on. No change in reading. Checked power at relay--about 14.5 volts there. Took truck to repair shop but their computer could not communicate with the GEM.

Any suggestions?? We are stumped!!!

 

Sounds like you have the ESOF tranfer case. If that's the case, try hitting the shift motor on the back of the transfer case. If it shifts in and out like it should, you may have a defective shift motor.

 

Just asked hubby--he said he's done that as well! Any other thoughts?? (Yes it is the ESOF transfer case)

 

Did you really change the shift relays in the small black box near the master cylinder?

With the engine RUNNING:

Put a test light on the two-wire connector going to the shift motor. Turn the ESOF **** to 4x4. Watch the light. Should light. Turn the **** back after waiting a minute. Should light again.

After all the parts you've thrown at it, it sounds like the shift motor or the switch (tells the GEM what gear it's in) on the shift motor itself is bad.

 

It may be in the transfer case itself. I took mine into a Ford garage and they added an additive to the oil and it worked well for 6 or seven years however it is back again. I was 20 miles from home so I decided to drive it home in low range taking my time, after several miles it came out. I tried all the reverse and neutral forward and reverse stuff but nothing. Have't dared to try it again.ha ha Good luck!

 

Usually, the shifting motor is the suspect.

 

Guys - the post is from 2010. I hope it is fixed by now!

 

That is true I was just saying that mine was still having the same problem. I had just been looking for some posts that explained what everyone else had done and thought it might be helpful to add that it could have been inside the transmission in case someone else had looked at it for info.