4x4 not working
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Fleet Mechanic
Joined: Jan 2012
Posts: 1,668
Likes: 13
From: Saskatchewan
4x4 not working
Hi everybody, I went out to a little 4x4ing today and my 4x4 wouldn’t engage. No light on the dash or anything. So I brought it home to check it out a bit and here’s what I’ve found. When I pulled back in the garage I shut it off to see if I could here the electric motor on the t case. KOEO I could here it working and the light came on the dash so all good right?? Well about the third time I tried nothing. Now I have no power to the electric motor on the t case. I tried tapping on the switch but it didn’t seem to help. Does anybody have a location for the relay that controls the t case motor? Or maybe a wiring diagram for this system. Thanks in advance.
Fleet Mechanic
Joined: Jan 2017
Posts: 1,665
Likes: 180
4WD control relays are located on the inside fender just to the front and below the master cylinder. The wiring runs down from there, all the way along the drivers side frame back to the trans. Any number of things could be wrong, and sounds as though you have some sort of connection problem somewhere. Or a chafed wire, though when I pulled all that out of mine, at 293K, no wiring was damaged at all.
Thread Starter
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Fleet Mechanic
Joined: Jan 2012
Posts: 1,668
Likes: 13
From: Saskatchewan
4WD control relays are located on the inside fender just to the front and below the master cylinder. The wiring runs down from there, all the way along the drivers side frame back to the trans. Any number of things could be wrong, and sounds as though you have some sort of connection problem somewhere. Or a chafed wire, though when I pulled all that out of mine, at 293K, no wiring was damaged at all.
Thread Starter
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Fleet Mechanic
Joined: Jan 2012
Posts: 1,668
Likes: 13
From: Saskatchewan
So now I’m really confused. I replaced both relays. No help. So I replaced the dash switch. Also no help. What I did find was there is no power to the dash switch what’s so ever. And I can’t find a wiring diagram anywhere for the switch and where it gets it’s power from.
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Fleet Mechanic
Joined: Jan 2012
Posts: 1,668
Likes: 13
From: Saskatchewan
So here’s what I’m thinking. The power comes from somewhere to the switch then from the switch to the relays. Relays to the motor right?? Anyways the problem must be before the switch on the dash I’m thinking.
Logistics Pro
Joined: Nov 2004
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A poster in this linked thread shows pics and diagrams
https://www.ford-trucks.com/forums/1...ont-shift.html
https://www.ford-trucks.com/forums/1...ont-shift.html
Thread Starter
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Fleet Mechanic
Joined: Jan 2012
Posts: 1,668
Likes: 13
From: Saskatchewan
A poster in this linked thread shows pics and diagrams
https://www.ford-trucks.com/forums/1...ont-shift.html
https://www.ford-trucks.com/forums/1...ont-shift.html
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Thread Starter
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Fleet Mechanic
Joined: Jan 2012
Posts: 1,668
Likes: 13
From: Saskatchewan
Just to try and get it working one last time before I went ice fishing today I messed around with the motor on the T case. I pulled the four screws off the cover and had a look. Nothing looked funny to me. Also pushed on the top plug in. Tried it and it worked. Not sure what the heck’s going on now but I used it all day and it worked fine probably 6 times. Guess I’ll have to see how it goes. 🤷🏻♂️
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J ballan, I worked on a fella's truck for a 4x4 inop complaint a couple years ago. When I went underneath to the shift motor on the T-case, I found the copper wire inside the insulation on at least 3 wires had turned to green powder. We had to cut back the harness quite a bit to find good copper and fix the corrosion issue that was keeping it from working. Either way, there should be codes in your 4x4 control module that you can pull with the right computer.
Thread Starter
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Fleet Mechanic
Joined: Jan 2012
Posts: 1,668
Likes: 13
From: Saskatchewan
J ballan, I worked on a fella's truck for a 4x4 inop complaint a couple years ago. When I went underneath to the shift motor on the T-case, I found the copper wire inside the insulation on at least 3 wires had turned to green powder. We had to cut back the harness quite a bit to find good copper and fix the corrosion issue that was keeping it from working. Either way, there should be codes in your 4x4 control module that you can pull with the right computer.
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