Hey guys, I have a 2005 250 5.4L auto, esof. i regularaly shift it in and out of four wheel drive throughout the summer, i shifted it in the other day to back a load of wood accross my yard and it won't come out of four wheel drive, shifted it to 4 low and it stuck there, i replaced the shift motor on the transfer case and it made no difference. the motor was shipped in 4 high and the case shifted fine with a wrench to put it in 4 high, still nothing works. i checked the fuses and they are good, the fuse in the cab (number 31 labled 4x4 in the owners manual) has no power to it and when i energize the circuit it makes the engine crank. is it just mis labled in the book or do i have a fuse panel problem? any ideas on where i go from here?

 

Might be one of the shift relays - see post 10 of this thread for a better explanation

https://www.ford-trucks.com/forums/1...t-working.html

Swap the relays to see if that takes care of the problem.

Post if this fixes it, or if you still have problems.

 

tryed swapping them and it made no difference, replaced them with a couple known good relays i had in my tool box, no difference. i do have power to the relays on terminals 87 and 86. so the switch or module must supply a ground to the coil to make it work

 

Check out post 8 in this thread - good test at the transfer case motor to help isolate the problem.

https://www.ford-trucks.com/forums/8...-problems.html

 

Also, wiring diagram and links to pinpoint tests in this link --- http://www.justanswer.com/ford/3iy8i...-time-gem.html

One of the diagrams is labeled for a diesel, but you can ignore that one, since it was a bit of red herring.

 

Sorry for the delay here but i've been busy and not had a chance to look at the truck. used the wiring diagrams and checked it out. found i have my powers and ground at the four wheel drive module. ohmed out the switch and it is good. checked wiring from the transfercase relays under the hood to the connector at the four wheel drive module and found i don't have continuity on one of the relay coil signal wires so the transfer case motor isn't geting a signal to come from low or four high to 2wd. thats as far as i have gotten today. I will probably just run a new wire from the connector at four wheel drive module to the relay to verify that will fix the problem.

 

Hey guys. Just wanted to update everyone. I ran a new wire between the four wheel drive module and the relay signal terminal. it is working like a charm now. Thanks for your help showing me the wiring schematics!

 

Cool! Glad you found the problem.

Are you going to stop with the new wire, or chase down where the break is?