1994 F150 XLT 5.0

In my experience if the transfer case motor makes a short or long shift or doesn't align the transfer case properly into one of the 3 positions for any reason the system will suddenly just be dead. I thought I had read somewhere when there is a bad shift it will default back to 2wd but in my truck that is not the case my system just dies (no lights on switches, no clicking of the module, no motor noise).

I spent hours and hours last summer diagnosing the whole system and couldn't find anything testing wrong I reassembled the whole system and it suddenly worked after finding no issues. I used it all hunting season this fall without issues until last week it stuck in 4x4 and the whole system was dead. After checking the fuses by necessity I got lucky and I pulled the transfer case motor to manually switch it to 2wd and what do you know the transfer case was not fully shifted into 4x4.

To move the transfer case motor back to the 2wd spot I applied 12v to the large yellow wire coming from the motor (I think that is pin 3 circuit 777? or so said another forum) and grounded the large orange wire (pin w circuit 778?). I just used a 12v battery I had laying around theoretically you could use the truck battery in a pinch. If you switch the wires the motor rotates the other direction. The motor has a built in stop at the 2wd position so I powered it up and let it rotate till it stopped, manually switched the transfer case to 2wd bolted it back up and suddenly the system works fine! I'd bet that was my original problem too. To bad I spent so much time testing everything in the whole system.

As to why my system short shifted it another question I don't have an answer to that but in the mean time I'll just carry the tools to realign the transfer case and motor to the 2wd position in the truck with me should this happen again.