ok guys heres the run down. I bought this 03 exc 6.0 psd 4x4 worked great then one day I needed it and it wasnt there. Im a diesel tech by trade but the Ford 4x4 system is confusing to me I grew up with push the lever and theres 4x4 not this switch triggers that switch runs that motor starts that vaccume and click theres 4x4. I checked fuses the dealer tells me theres no relay? seems like there would be? t-case motor was burnt up so I replaced that still nothing. I went to the wrecking yard grabbed a gem module out of another 03 6.0 still nothing I have good vaccume my defroster vents and ac switch around quickly. ive traced just about everything I can think of. now heres my dilemma. I have 12 volts going to the switch and a good ground. when I turn it to 4x4 it drops to 6 volts? then when I hit low range it drops to 1.6 volts whats up with this? oh ya and ive swapped out multiple 4x4 dash switches.

when I start up the rig the 4x4 lights check in then go off im assuming this means things are kinda working properly? I can jump 12 volts across the t-case motor and it will click into 4x4. driveline locks up and the 4x4 dash light comes on ( any ideas yet)? I can reverse the polarity across the t-case and it hits low range. light and all. Im completely lost now can anybody help me out? y will nothing happen when I turn the dash switch.... Thank you to all who can help me

 

If his upload works, this should help. You wont be able to use the hyperlinks as the program is on my PC. You ca read them, then scroll to them. Good Luck!

 

That info helps amazingly now my question is can anybody tell me the location of the transfercase shift relays? everything seems to be working when Im testing by the book but it wont let me referance a pic. of relay locations.......

 

You want Auxillary Relay Box 3.

e3o~us~en~file=e3oen09g.pdf

e3o~us~en~file=e3oen04o.pdf~gen~ref.pdf

e3o~us~en~file=e3oen04i.pd.pdf

One more in the next Post.

 

The rest of the story.

e3o~us~en~file=e3oen04g.pdf

 

The owners manual says that before you bring in your rig for service on this issue to allow it to engage many times before you seek help. I did the same on my eX last year in the snow & it took about 15 miles until it was working correctly. Now I check it often & it stays functional.

live long and prosper.

 

Thanks Rickx the guidance was excellent I found a short in one of the plugs going into the Gem box....... to be honest as long as it takes to run through the diagnostic process with all the wiring I could have spent a small fortune at the dealer.... Again many thanks....

 

I've gotten a lot of help from FTE. I figure it's the least I can do.... to help others.

 

i am having the same problem.. can you tell me wht you did to fix this? thanks much