4x4 low range light on

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Jun 14, 2003 | 07:07 PM

jayrus

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4x4 low range light on

Hey everyone,newbie here with a big problem.I have a 97 Expy with the 4.6.I was driving the other day when the 4x4 and low range lights came on.I know it is not in 4 low because I know what 4 low feels like.I took it into some gravel and found it wasn't in 4 wheel drive at all.Switching the switch and disconnecting the battery didn't help.I did some tests and thought I traced the problem to the transfer case relays.A trip to the dealer and $75 bucks later and the problem was still there.Everything seems fine now until I try to engage 4 hi or 4 low.When I switch into either one of these settings the transfer case relays click 4 or 5 times and then the 4x4 and low range lights stay on.If I switch it to a4wd or 2wd they stay on.It never engages 4wd.I powered the shift motor directly and it shifts into 4wd.I tested the switch with an ohm meter and it is working fine.I am at a dead end,any ideas?Thanks in advance.

Jun 14, 2003 | 10:03 PM

BigMattXXL

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From: Annapolis, Maryland

4x4 low range light on

Jayrus-

First off, welcome to FTE! I'm sorry to hear about your problem. Have you tested/replaced any of the relays? Sounds like your hunch was right. What did the dealer tell you?

Obviously, if you can power the shift motor directly, then it works, but the signal isn't getting there. I, however, aren't too great (I'm not bad either, but I'm not great) with electrical stuff. This might be a job for Racerguy. I'll see if I can summon him.

XXL

Jun 15, 2003 | 12:10 AM

jayrus

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4x4 low range light on

Any help would be great.I did replace the transfer case relays as well as the solid state relay(they are serviced together).I couldn't believe they put the relays in the bowels of the dash.The only other item I thought might be bad is the GEM,but I did get a shift motor plate shorted to ground code.The only problem is the code is intermittant.

Jun 15, 2003 | 02:25 AM

Racerguy

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4x4 low range light on

Sure Matt, only come calling when you have a difficult one

Jayrus do you know what the code was that was retrieved? The actual number please if you have it.
The shift plates in the motor can cause problems which will make the lights do strange things but the GEM can also do that.
I think the first thing I would try is unplugging the 4x4 light switch on the front of the transfer case, sort of above the front driveshaft. If the lights go out then you could replace the switch and probably change the oil in the transfer case. It seems that moistuer acuumulates in the switch and causes strange problems. Believe it or not the 4x4 switch can cause the widnshield wipers to not work unless you have it in 4x4. It has to do with the way GEM gets it's signals.

Jun 15, 2003 | 08:21 AM

jayrus

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4x4 low range light on

I don't remember the exact code number,but I will run by the shop and check it again.I did remember to check the grounds behind the drivers kickpanel,but I don't know if there are others.I will also change the fluid while I am at the shop.Thanks guys,I will keep you posted.Wish me luck.

Jun 16, 2003 | 05:00 PM

jayrus

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4x4 low range light on

Both the codes were in the 1800's.I believe they were 1839 and 1867.One was Shift motor circuit problem,the other one was shift plate shorted to ground.I pulled the shift motor off and had a buddy switch it through the cycle and the motor moved fine,but it wouldn't go all the way to 2 high.The shaft in the case turned with no problem.I unplugged the harness and powered the motor and it went through the full cycle with no problems.I then cleaned the contact surface of the motor and the case and reinstalled the motor.I tried it again and everything worked as it should,no more shifting problems,and all the lights were working correctly.I took it off the jackstand and took it outside shifted into 4hi and it started acting up again.I can't get it to act up consistantly(sp).Sometimes it works and other times it doesn't.I hesitate to replace the GEM module because everything else works fine.Can there possibly be a problem in only one circuit in the GEM and it doesn't affect anything else?Any ideas?

Jun 17, 2003 | 12:40 AM

Racerguy

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From: BC, Canada

4x4 low range light on

Next step might be to try cleaning the contact plates inside the motor, under the round black cover. If you do a search in the Explorer forum I think you might find instructions on that.