2001 Transfer Case Problem
Thread Starter
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FTE Legend
Joined: Aug 2004
Posts: 37,887
Likes: 20
From: North Central Rural Sask.
I havent done any more testing yet cause my father hasnt come my way lately, but hoping to get some more ideas.
As it sits everything works out of the gem except the 4x4. I was so I just keep thinking I should have found the problem with all the testing ive done.
Senior User
Joined: Sep 2008
Posts: 419
Likes: 0
From: Alfred NY and Long Island
Alright ill throw some advice out there for ya since I just battled my 4wd a month or so ago.
Since you have replaced the ESOF motor then you know to to take it out. Can you take the motor off, have your pops flip the switch and see if the motor moves? It will be a very slight movement, doesn't take much at all to get into 4wd.
If the motor moves then you have a t-case problem.
Next stop take a 14mm open end wrench and manually engage the 4wd system, if I remember correctly you pull the wrench down towards the ground 1 click and you are in 4wd High.
So if the T-case does engage and work, then you don't need one of those.
Personally I would look at the relay box under the hood. Mine was all corroded and full of crap. I would spend the 12 dollars and replace the relays, and really make sure those connections are spot on.
Well that's all the advice I have for now. Hopefully it helps.
Since you have replaced the ESOF motor then you know to to take it out. Can you take the motor off, have your pops flip the switch and see if the motor moves? It will be a very slight movement, doesn't take much at all to get into 4wd.
If the motor moves then you have a t-case problem.
Next stop take a 14mm open end wrench and manually engage the 4wd system, if I remember correctly you pull the wrench down towards the ground 1 click and you are in 4wd High.
So if the T-case does engage and work, then you don't need one of those.
Personally I would look at the relay box under the hood. Mine was all corroded and full of crap. I would spend the 12 dollars and replace the relays, and really make sure those connections are spot on.
Well that's all the advice I have for now. Hopefully it helps.
Thread Starter
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FTE Legend
Joined: Aug 2004
Posts: 37,887
Likes: 20
From: North Central Rural Sask.
Thanks for the input Dennis, I will definately take the motor out next time and recheck it. We never did actually test the mechanical aspect of the transfer case!
For the relay box under the hood, I tested wires there, and cleaned that all up. It was actually in very good condition under there. Still sprayed contact cleaner under there then used compressed air to get it perfectly dry.
For the relay box under the hood, I tested wires there, and cleaned that all up. It was actually in very good condition under there. Still sprayed contact cleaner under there then used compressed air to get it perfectly dry.
Thread Starter
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FTE Legend
Joined: Aug 2004
Posts: 37,887
Likes: 20
From: North Central Rural Sask.
Ok, so tonight my folks came to visit us, and I did a little testing. According to the esof 4x4 diagram that I have downloaded from here, every single wire is good.
The transfer case manually shifts into 4x4 high and low, so its not mechanical.
Guess tomorrow I will try to test a few more things with the multimeter, and its looking like we might have to take it in to the dealer.
Almost starting to wonder if Ford sold us the wrong GEM?
Usually I can trouble shoot electrical pretty good, but this one has me stumped!
The transfer case manually shifts into 4x4 high and low, so its not mechanical.
Guess tomorrow I will try to test a few more things with the multimeter, and its looking like we might have to take it in to the dealer.
Almost starting to wonder if Ford sold us the wrong GEM?
Usually I can trouble shoot electrical pretty good, but this one has me stumped!
Senior User
Joined: May 2011
Posts: 454
Likes: 0
From: Portland, OR
That could certainly be the case. Looking forward to seeing what you find out there.
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Thread Starter
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FTE Legend
Joined: Aug 2004
Posts: 37,887
Likes: 20
From: North Central Rural Sask.
Im looking forward to finding the problem as well! This one is frustrating.
Almost trying to come up with a custom linkage to put a stick through the floor!
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FTE Legend
Joined: Aug 2004
Posts: 37,887
Likes: 20
From: North Central Rural Sask.
Ok so abit of a update. Pulled the shift motor off just to triple check it on my own truck, it worked.
So we put everything on my dads truck back together again, I tested the relays one more time, everything has checked out good.
Turned the truck on and it engaged to 4x4!
Now it wont disengage haha. So the plan is to take the shift motor off again, work the transfer case in and out of 4x4 hi and low while lubing that shaft, triple check the electrical conector at the top of the motor.
Only other thing I did is took off the esof connector on the passenger side inner fender, and recleaned that.
Nice to see that with all of our screwing around, something engaged it, so least its not a total lost cause yet.
So we put everything on my dads truck back together again, I tested the relays one more time, everything has checked out good.
Turned the truck on and it engaged to 4x4!
Now it wont disengage haha. So the plan is to take the shift motor off again, work the transfer case in and out of 4x4 hi and low while lubing that shaft, triple check the electrical conector at the top of the motor.
Only other thing I did is took off the esof connector on the passenger side inner fender, and recleaned that.
Nice to see that with all of our screwing around, something engaged it, so least its not a total lost cause yet.
Thread Starter
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FTE Legend
Joined: Aug 2004
Posts: 37,887
Likes: 20
From: North Central Rural Sask.
No, we didnt replace any relays yet. Just tested them a couple times, and they all tested fine.
We left my dads truck with the transfer case engaged, and when he gets home (2.5-3 hour drive) hes gonna screw around in the snow with it, and let me know if it moves or whatnot.
We left my dads truck with the transfer case engaged, and when he gets home (2.5-3 hour drive) hes gonna screw around in the snow with it, and let me know if it moves or whatnot.
4wd Low
Joined: Jul 2014
Posts: 13
Likes: 2
My suggestion is to go on and build and install a floor shifter. Good luck whatever you decide.
Thread Starter
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FTE Legend
Joined: Aug 2004
Posts: 37,887
Likes: 20
From: North Central Rural Sask.
I ran around with this problem for two years. I’d work on it until I’d be so frustrated I couldn’t stand it and then give up. Start tracing wires and relays and switches only to find nothing wrong and give up again. The last time I worked on it for a couple of weeks and gave up again without finding the problem. Built and installed a floor shifter and solved my problem. I have to get out and lock the hubs manually but when I want it to go into 4wd it goes into 4wd. No questions asked. 2000% better.
My suggestion is to go on and build and install a floor shifter. Good luck whatever you decide.
My suggestion is to go on and build and install a floor shifter. Good luck whatever you decide.
You happen to have any pictures you could share of what you built?