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Ok so my 4wd suddenly stopped working, 2005 excursion 6.0, my dash lights come on when I turn the key, but my switch doesn't do anything.
I have power to my 4wd selector switch. I checked I believe it's fuse 11 and 31 both fuses are fine (both say they are for 4x4 according to manual) but I don't have have power to the #31 fuse.
I tested for power at both wires on the transfer case actuator with the truck running in neutral and a friend turning the 4wd selector.
I pulled out every square normal sized relay under the hood (i didn't test the small rectangle ones, pins are too small) and tried to find continuity between the two wire plug at the transfer case actuator and every pin. none have continuity. all the relays click when I apply power and ground to activate them.
I did have a recent issue with the driver side transfer case plug the lock had broken and it vibrates loose, losing 4x4. so several weeks ago I used shoe goo to hold it securely in place and it seems to still be well connected.
I have 3 relay boxes between the firewall and battery driver side, for some reason I keep finding info that is different on the relay positions and is giving me a hard time to diagnose when I don't know what is what.
I did have a recent issue with the driver side transfer case plug the lock had broken and it vibrates loose, losing 4x4. so several weeks ago I used shoe goo to hold it securely in place and it seems to still be well connected.
You gotta start there. Were you able to clamp/rubber band/tape it until the goo set up?
I'm sorry I just got in from doing 4 cv shaft seals and two pinion seals on a 2004 explorer (boooooo). I forgot to get a photo I will get one in the morning for you