Okay, so we have purchased a 4x4 shift on the fly button. And that was sadly not the problem. We have no clicks, no lights, basically no nothing involving the 4WD. We have locking hubs and have checked all fuses. Main question is how do we test the new control module light system (just purchased today) ? Also, if any new thoughts on what else our issue could be.

 

A DMM can be your best friend when it comes to electrical problems. Have you bench tested the actuator on the t-case? If you live anywhere there's salt, the actuators tend to go bad in these.

 

Sorry, not to familar with the terms exactly. DDM?? And also is there a chance that the actual wires could be bad. He just did the test and the light on the control module does not keep a constant flash for the advised flash per second. I am beginning to think that maybe the connectors could be the issue??

 

connectors could very well be an issue, along with the wires. a DMM is a digital multimeter. it'll test for voltage, resistance, and amperage in an electrical system. i'd go wire by wire and test for voltage. you don't want to see an ohm or more of resistance in any wire. ford connectors aren't that great to begin with (which i believe is their only downfall in this era).

 

DMM= Digital Multimeter

 

Okay, we will try that. And we will probably try running 12v to the t-motor to see if that will possibly engage the motor. And do you possibly know where the GEM module is located or/and a picture would be fantastic.

 

if you can get the actuator off the t-case, then leave it plugged in and have someone hit the 4x and 2x switches. if the motor turns, then the problem is inside the t-case. if the motor doesn't turn, then check to see if the motor will turn by hand. if it can turn by hand, then the motor is not likely the issue. i *think* the GEM is up in the dash on the driver's side.

 

If the motor doesnt want to be hand turned should we try to hand turn it

 

i dont believe you will be able to hand turn the motor. if you are able too it will not move easily. the motor is able to turn the gear inside very easily, however the motor is not easily tuned by the gear. confusing huh? Anyways what im trying to say is just because you cant turn it dose not mean the motor is bad.
Now as far as having no 4x4 lights when you turn on the key is an indication that the control module is bad. i believe when you turn on the key the lights on the buttons themselves are supposed to flash very briefly, like not even enough to fully illuminate. if yours do not do this than your problem most likely lies in that area

 

Problem come on sudden or never worked as long as you owned the truck? Just buy the truck?

If never worked or been a while sense attempting to use 4w might be stuck from lack of use, not uncommon in that system.

Did you try simply smacking the shift motor with a hammer couple times (not hard just create some vibration) see if it shifts or attempts to?

Light is not going to light up until motor successfully shifts.

IIRC light only "flashes" if/when computer looses track of shift motors location, if it had not moved it the computer knows its location IE; 2H, it wouldn't flash.

 

are you sure danr1? every one ive ever driven the lights on the buttons themselves flash very briefly, not even enough to fully illuminate, just for a spit second right when the key is switched on

 

No I don't recall that and while my experiences have been with little Broncos and Explorers (older and newer then the OP's truck here) they all use the same system/shift motor.

The light on the dash as I recall only lights up if the TC is in 4wheel. No light in 2H and light "flashes" when computer doesn't know where the shift motor position is.
Might "flash" if gear change is attempted say 2 to 4H for example and motor doesn't move at all IE; fails to shift, but don't recall that as fact.

 

i just checked my dads ranger and it does indeed blink the lights just for a split second when the key is switched on. it is very easy to see in the dark. turn the key on and off and watch it.