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4x4 not engaging t case

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Old Sep 24, 2019 | 06:48 PM
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4x4 not engaging t case

Have a 02 f250 CC in my shop right now that I’m working on for a guy. 4x4 not working is one of the many problems I’m addressing. Both high and low range lights come on when switching to run position when turning the key on so the lights work. Checked the 30 amp fuse under the hood and I believe fuse 28? Under the dash and all is good there also. Swapped both the relays under the hood with 2 out of my 99 that I know are good and I don’t get any click on those when I turn the switch. Also swapped the switch out of another working truck with no change and last I took the TC motor off and plugged it into my personal truck and it works and functions as it should and make my 4x4 lights function on my dash. So where do I go from here? Is it the body module? Need some direction here. I hate ESOF what’s wrong with pulling a lever. Thanks
 
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Old Sep 24, 2019 | 08:27 PM
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Check the connections under the truck.
Mine was doing the same thing and it turned out to be a dirty connector.
 
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Old Sep 24, 2019 | 09:01 PM
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Sounds like possible a failing GEM module (body control module).
Are some of the other issues electrical?
 
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Old Sep 25, 2019 | 12:11 AM
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No other electrical issues, everything else is mechanical that I’ve repaired(glow plugs, pinion seal, radiator, etc). Plugs were clean under the truck and were fastened tightly together when I took the motor off the transfer case.,
 
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Old Sep 25, 2019 | 10:27 AM
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Remove the shift motor from the transfer case and have someone switch from 2HI - 4HI - 4LO and see if the shift motor moves. If it does not, you are getting closer.

If it does move, see if you can manually shift the transfer case. If you cannot, you are getting closer.

If it does move, start looking toward the hubs, vacuum pump and system. Do the hubs, axles lock up or do they free spin all the time?

Another thing to consider, sometimes 4HI will not engage unless the truck is moved forward or reverse a bit.
 
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Old Sep 25, 2019 | 05:59 PM
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From: lakeland, Tn
Originally Posted by Sous
Remove the shift motor from the transfer case and have someone switch from 2HI - 4HI - 4LO and see if the shift motor moves. If it does not, you are getting closer.

If it does move, see if you can manually shift the transfer case. If you cannot, you are getting closer.

If it does move, start looking toward the hubs, vacuum pump and system. Do the hubs, axles lock up or do they free spin all the time?

Another thing to consider, sometimes 4HI will not engage unless the truck is moved forward or reverse a bit.
I mentioned in my original post I moved the motor to another working truck and it worked fine on it. Also the transfer case shifts easily from two to four to four low
 
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Old Sep 25, 2019 | 06:06 PM
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Originally Posted by Bluebronco85
I mentioned in my original post I moved the motor to another working truck and it worked fine on it. Also the transfer case shifts easily from two to four to four low
I realize the motor works and operates as designed on another truck, but there is no mention if the motor works on the problem truck. I was simply trying to help you isolate the problem area, or at least point you in the right direction.

Any comments on anything else I mentioned other than the T case operating?
 
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Old Sep 27, 2019 | 08:55 PM
  #8  
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From: lakeland, Tn
Originally Posted by Sous
I realize the motor works and operates as designed on another truck, but there is no mention if the motor works on the problem truck. I was simply trying to help you isolate the problem area, or at least point you in the right direction.

Any comments on anything else I mentioned other than the T case operating?
Sry if I sounded rude, was a long aggravating day when I posted that my 99.5 got rear ended and another truck I’m working on other than the one I was posting about was turning into a can of worms. But I did find the problem with the tcase on the 02. 1 of the pins on the 6 pin plug was loose. When I put the meter on it to start testing things I noticed the wire was moving around loosely. Got it back in place and a dab of electric grease and she’s working great. Thanks for the help again.
 
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Old Sep 28, 2019 | 11:53 PM
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Electric grease gonna hold long term? Maybe RTV?
 
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Old Sep 29, 2019 | 11:43 AM
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From: lakeland, Tn
Originally Posted by aawlberninf350
Electric grease gonna hold long term? Maybe RTV?
I didn’t use electric grease to hold it together. I fixed the pin then a dab of the grease to prevent rust, corrosion, water intrusion.
 
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