I went ahead and ordered the new motor.
Sous, thanks for the link. I saved it to my truck folder.
I am pretty sure the motor was shot but if I install the new one and still have issues this .pdf file will be just what the doctor ordered.

Hopefully I will be able to locate a Factory Service Manual for my truck. I'll keep looking.

 

good condition used ones on ebay is your best bet.

 

@jimjokjv , I was just informed the ESOF Diagnostic uploaded by @Colorado Horseman was for a 2007, but the 2002 version is coming soon. I have removed the 2007 version from the Tech Folder and will update it with the 2002 as soon as he has the time to upload the proper year.

He told me that the 2007 may still be relevant to your troubleshooting, so you might give it a glance if you get stuck again.

I apologize for the confusion and assure you we will get this right.

 

I'll watch for the correct version. Thanks for the heads up.

 

@jimjokjv , Colorado Horseman came through for us today! I have updated the Tech Folder link (which is below) to reflect the 2002 ESOF Diagnosis procedures.

https://www.ford-trucks.com/forums/a...8&d=1579914736

 

Houston, we have a problem!
I was getting ready to install the new motor assembly when I noticed this.


Apparently the wire loom had detached from the retention clips and was laying on top of the front driveshaft. Not sure how long it was like that but it definitely wore through the wire loom and wire insulation.



Of course this explains the 30 amp fuse blowing and nothing happening when turning the 4x4 switch.
I tried a quick fix by splicing the wires that were destroyed and wrapping the others with electrical tape. But still not showing any power getting to the motor connectors. Wondering if the short may have caused problems elsewhere in the harness as well.
Tomorrow I will trying checking for continuity on the harness.

 

The ESOF document is a great help as I continue to hunt down this problem.
Yesterday I discovered the continuity check of the 4x4 relay ground pins was out of spec. Supposed to be less than 5 ohms and mine were over 20 ohms. Cleaned the ground contact points throughout the engine compartment and that resolved the issue with readings less than 1 ohm. Hoping for the best I cleared the codes and rechecked the system - nothing.
Today I will move on to the next specified test in the ESOF procedure. This systematic approach is tedious and time consuming but obviously the only way I will find this issue.

 

exactly why i recommend having some sort of access to the the FSM. most people do not realize how much there is to the ESOF system until they have to try and fix it. it most certainly is not just a simple on off switch with a easy answer to fix.
i have tried in the past to walk people through the step by step, just doesn't work well on the FTE forum format.

 

You will get it! If nothing else you are learning a great deal about the ESOF system and a great deal about your truck. Look at this as a learning process that is bound to bear fruit at the end of it. You could make moonshine out of that fruit if you like...

Just keep at it Jim, we are all watching and providing assistance when and where we can.

 

I am starting to think you have a stockpile of these manuals and are selling them on eBay or something as many times as you have mentioned it! Sure, it would be great if we could all have a service manual in front of us, but as Jim already indicated they are very expensive and hard to come by.

Alternatively, FTE members that do in fact have a service manual have been nice enough in the past to either upload the necessary pages or scan and upload the sections for the FTE public to use. This not only creates and avenue for the original help seeker to find help and guidance, it allows for FTE'rs to have help for years to come...

Posting does not help in anyway, shape or form. Posting information you have taken from the "manual" does on the other hand and I always encourage a positive outcome to issues or those seeking guidance.

Take the recent post by AubieTN for example. He took the time to develop his own fix action for a poorly designed hose and ran it to ground. He then shared the information with us so that we could all benefit from his design and research. This is a great example of what we at the FTE are trying to sponsor.

Another recent example is in this very thread... Thanks to Colorado Horseman the FTE now has available to use the 2007 and 2002 ESOF troubleshooting guides.

NicMike also commented about how he posted some of the early model year ESOF troubleshooting information in the Excursion forum, which I have linked to the 7.3L PSD Tech Folder. Telling someone does not help, no matter how many times you say it. In the military when traveling abroad, they would always remind us that just because you say something louder and slower does not mean the person you are speaking to understands your message because they still do not speak the same language.

 

I pulled the entire transmission harness from the truck. Did find one spot where the wires had fused together. Repaired and rechecked for proper continuity.
Followed the ESOF manual in checking the system as best I could. The problem being that the ESOF is for a 2002 and my truck is a 2000 and the connectors look different than the diagrams. Wire colors were correct so I went with that for pin location.
Everything checked out but after reassembly, the 4x4 switch does nothing.
Pulled the dash to inspect the wiring to the switch and all visually appears to be in good condition. So the search and saga continue.

 

@jimjokjv I have a 2000 with ESOFand the manual for it. What pictures or diagrams of which connectors do you need?

 

@FordTruckNoob I will send you a PM in a few minutes. Maybe we can work something out that benefits Jim and many others...

EDIT: Jim, we are working on getting you the information that should help you out immensely. I will post back here when FordTruckNoob and I have completed the task.

 

@Sous Here's that teaser pic I couldn't send via PM.

 

This will be a nice resource to have in the Tech Folder along side the 2002 ESOF Diagnosis procedure provided to us by Colorado Horseman.

Thank you Leonard, and you know how to get in touch with me via text, email or PM when you are ready to publish it or want me to help package it together for the FTE to use.

It is people like you (and many others here) that make the FTE a great place!