4X4 Issues
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Junior User
Joined: Dec 2007
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4X4 Issues
Ok, need a little bit of help on this one. My 4x4 decided to kick the bucket some time ago, and I'm having a little bit of an issue reviving it. The transfer case is not shifting at all. Not even trying. The motor is good, I can jumper the relays and get the case to shift. The wiring and encoder is also good, because all of the lights come on at the right time. Once I shift it once, the "4X4" light comes on, shift it again, "Low Range" shows up. Just like its supposed to, right? So I bench test the relays. Functioning perfectly. But I replaced em with some ones I had on hand anyway. That didn't do it. Maybe it's the switch. Test it with some of the specs that I found here, its fine. So at this point. I'm down to the GEM, right? And if I can't find the exact one that I have on there now, I'm going to have to pay the wonderful stealership to program it for me? Or is there something else that I'm missing?
Lead Driver
Joined: Jul 2003
Posts: 7,404
Likes: 52
From: Wheatland, Mo
Not sure if I misunderstood what you put in your post but sometimes the motor itself can get dirty and not actually activate. Some have removed the transfer case motor that actually kicks it in, clean it and all is good.
If you checked the switch, the wiring and the relays, then that is really the only thing left.
However, if all this works and you are getting the lights on the dash but no front wheels getting power, then another issue with it not going into 4x4 could be that there is a vacuum leak and the hubs aren't engaging. One way to test is to turn on your heater to floor, then engage the 4x4 with the switch. If after a fews seconds the air for the heater changes on it's own from floor to defrost, then you have a vacuum leak and the hubs aren't engaging.
If you checked the switch, the wiring and the relays, then that is really the only thing left.
However, if all this works and you are getting the lights on the dash but no front wheels getting power, then another issue with it not going into 4x4 could be that there is a vacuum leak and the hubs aren't engaging. One way to test is to turn on your heater to floor, then engage the 4x4 with the switch. If after a fews seconds the air for the heater changes on it's own from floor to defrost, then you have a vacuum leak and the hubs aren't engaging.
Postmaster
Joined: Jan 2009
Posts: 2,667
Likes: 1
From: Glen Rose,Texas
Not sure if I misunderstood what you put in your post but sometimes the motor itself can get dirty and not actually activate. Some have removed the transfer case motor that actually kicks it in, clean it and all is good.
If you checked the switch, the wiring and the relays, then that is really the only thing left.
However, if all this works and you are getting the lights on the dash but no front wheels getting power, then another issue with it not going into 4x4 could be that there is a vacuum leak and the hubs aren't engaging. One way to test is to turn on your heater to floor, then engage the 4x4 with the switch. If after a fews seconds the air for the heater changes on it's own from floor to defrost, then you have a vacuum leak and the hubs aren't engaging.
If you checked the switch, the wiring and the relays, then that is really the only thing left.
However, if all this works and you are getting the lights on the dash but no front wheels getting power, then another issue with it not going into 4x4 could be that there is a vacuum leak and the hubs aren't engaging. One way to test is to turn on your heater to floor, then engage the 4x4 with the switch. If after a fews seconds the air for the heater changes on it's own from floor to defrost, then you have a vacuum leak and the hubs aren't engaging.
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Junior User
Joined: Dec 2007
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No, its not vacuum related. Vacuum no longer does anything with my 4x4, as I've put Warn hubs on. The transfer case motor does work, it just doesn't work with the switch. I can make it shift by jumpering across the relays, but I'm not getting any signal out to the relays. And the switch in the dash is good. I'm hoping its not the GEM, but I'm guessing that's about all that's left to go wrong, isn't it?
Elder User
Joined: Nov 2006
Posts: 799
Likes: 0
From: Mission, BC
when i bought my truck , 4x4 wasnt working, but the lights would come on. the electrical plug on the transfer case was not seated correctly. take a look at the plug, check for corrosion, use a little piece of sandpaper or soemthing, shove it back on, make sure you hear it click. if its not that, you probably have power going to the plug, get a buddy and a multi meter and see that the voltage changes as you switch it from off to 4wd....
Post Fiend
Joined: Nov 2007
Posts: 9,549
Likes: 14
From: Payson, AZ
When you bench tested the relays did you check for continuity
between 30 and 87a to make sure the break contact was closed
when relay was non-operated.
Also make sure the relays you used for replacement have post 87a.
Four post bosch type relays can be replaced with 5 post relays but
5 post relays cannot be replaced with 4 post.
between 30 and 87a to make sure the break contact was closed
when relay was non-operated.
Also make sure the relays you used for replacement have post 87a.
Four post bosch type relays can be replaced with 5 post relays but
5 post relays cannot be replaced with 4 post.
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Junior User
Joined: Dec 2007
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Relays checked good for both NO, and NC contacts. Like I said, I'm confidant in the wiring and plugs at the motor, because everything down there does what its supposed to. If I jumper the relay to lock in 4x4, the motor runs, I hear it switch gears, and the 4x4 light comes on. If I then jumper to unlock, the motor runs, I hear it, light goes out.
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Post Fiend
Joined: Nov 2007
Posts: 9,549
Likes: 14
From: Payson, AZ
Can you actually feel the relays operate when someone turns the switch? If you can jumper at th relay sockets and things work it sure points to a relay not operating.
I had a similar problem but neither 4x4 nor Low Range indicator lamps came on. I bench tested the relays and before plugging them back in I cleaned the spade posts on the relays and the relay sockets. Got lucky I guess because it has worked ever since.
I had a similar problem but neither 4x4 nor Low Range indicator lamps came on. I bench tested the relays and before plugging them back in I cleaned the spade posts on the relays and the relay sockets. Got lucky I guess because it has worked ever since.
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Thread Starter
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Junior User
Joined: Dec 2007
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No. The relays don't operate. They aren't getting coil voltage to operate. The relays are good, the wiring and connections to the t-case motor are good, its just not sending the signal out to the coils to shift. And since the switch in the cab also tested fine, I guess that's why I was starting to think that the GEM is shot. From the wiring diagram that I have, the switch tells the GEM what gear you want to be in(from the switch position), and the GEM is "supposed to" activate the relays to get the t-case to match what the switch says you want. Somewhere in there, we have a bit of a disconnect.
Post Fiend
Joined: Nov 2007
Posts: 9,549
Likes: 14
From: Payson, AZ
Have you been able to check the connections on the underside of the relay box? Hate to overlook anything before replacing the GEM. After all this whole troubleshooting exercise is in hopes of proving its not the GEM.
Post Fiend
Joined: Nov 2007
Posts: 9,549
Likes: 14
From: Payson, AZ
I sure hope you find a problem that is not the GEM. Good Luck.
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Junior User
Joined: Dec 2007
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Been a while since I was on here, but yep, it was indeed that cheap little unit called the GEM. Local dealer wanted $650+ for it. Ed was considerably more reasonable. $309 or something like that. Got my keyless entry to work again as a bonus. Thanks for the help, guys.
Post Fiend
Joined: Nov 2007
Posts: 9,549
Likes: 14
From: Payson, AZ
Been a while since I was on here, but yep, it was indeed that cheap little unit called the GEM. Local dealer wanted $650+ for it. Ed was considerably more reasonable. $309 or something like that. Got my keyless entry to work again as a bonus. Thanks for the help, guys.
Did the GEM come programmed?