4x4 Issues

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Mar 29, 2018 | 03:42 PM

ChiefO

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4x4 Issues

I have a 2000 Ford Excursion Limited 6.8L 4x4 that is experiencing some 4x4 issues. This started when I went to get in the truck one day and the 4x4 light was on but the truck was not in 4x4 mode. I worked through every possible scenario of backing up, switching in neutral, you name it, I tried it. Eventually the light went off but the truck would not shift into 4x4. I had it diagnosed by a local mechanic who replaced the shift motor but it did not fix the issue. He stated that his research pointed to a short somewhere in the wiring going to the transfer. The vehicle will shift into low range when 4 LOW is selected but it does not engage the front axle. I finally had a ford dealership check it out and they have stated that it is the GEM module ($525 parts/$441 labor). I've found GEM modules that run $325-$450 and I do the labor myself. I've read the information that Nicmike had posted and will try to do some more investigation on my own to verify if this is the issue as I don't want to just start throwing money at this issue without a clear solution on the horizon. Does anyone have any recommendations on what I should check or verify before go down this road?? Thanks for any info or advice you can provide.

Mar 29, 2018 | 04:12 PM

Nicmike

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Joined: Feb 2012

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From: Western AR

Chief, I will post up the test out procedures for you when I get home. I have posted them in the 7.3L section a few times in the past, so if you want to search there, you should be able to find them in a few minutes. That procedure/s will tell you where to start looking to narrow your search right off the bat. Once you find a failure point, it will refer you to a "pinpoint test". I can also post whatever "pinpoint test" you might need. There are quite a few for the 4x4 system and its failure points.

Mar 29, 2018 | 05:59 PM

Stewart_H

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Joined: May 2004

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From: Central Coast of CA

Quote:

Originally Posted by Nicmike

Chief, I will post up the test out procedures for you when I get home. I have posted them in the 7.3L section a few times in the past, so if you want to search there,

I went and did.

Mike, here's a stand-alone thread I created from your posts: https://www.ford-trucks.com/forums/1...l#post17893773

Please feel free to expand on it. I'll be adding it to the tech folder later today when I have more time.

Stewart

Mar 29, 2018 | 07:26 PM

Nicmike

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Joined: Feb 2012

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From: Western AR

Stewart, you are pure awesome. Thanks for that!

Mar 29, 2018 | 08:05 PM

pirate4x4_camo

Lead Driver

Joined: Apr 2011

Posts: 8,259

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From: Northern California

Keep a swap to a manual shift case as an option if cost get to absurd on the GEM.
depending on where you live a NP271 can be bought for a few hundred bucks.

Mar 31, 2018 | 10:05 PM

ChiefO

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Thanks guys. The diagnostic write up is pure gold. Camo I remember you from my rock crawling days on pirate. I’ve sourced an NV 271 and complete linkage setup for $300. I’m thinking I’ll go that route and be done with it. I’d rather be able to grab a stick and turn a hub and know I’m locked in vs hoping the blasted electronics work. Don’t get me wrong they have their place but that’s one area that seems to be extremely costly and frustrating with these trucks.

Mar 31, 2018 | 11:32 PM

pirate4x4_camo

Lead Driver

Joined: Apr 2011

Posts: 8,259

Likes: 346

From: Northern California

Chief,

ya it’s me.

I’ve never trusted the ford electro-vacuum 4x4 system as these trucks approach 20 years old they are increasingly less reliable. I ditched the vacuum part long ago, wish somebody would make a Manual shifter to replace the computer controlled servo shifter..... the fewer electronics and computers the better in my opinion.