Recently my '93 Explorer stopped shifting into 4x4 range when I pushed the switch. I think I hear the solinoid activate when I depress the switch. Where should I start troubleshooting? What are the least expensive problems I could have? Thanks

 

My 92 explorer is having the same problem, nothing happens when I push the button. People have suggested checking everything from fuses to the electric shift module to wiring. Most suggestions are far to complicated and expensive for me, Good luck!
Mel

 

My 92 had the same problem. I found the fix on this web site but have forgotten the location. It gave detailed instruction for removing the shift drive motor. I did that without even raising the vehilce but it is easier if you have a little more room.
The 4X4 has shifted fine even since.

The problem lies in the contacts getting dirty or actually getting out of alignment. The shift motor has as part of its housing the contacts in a cap. The cap is held on by three screws pressing down on the cap. This way of attachment can allow the cap to rotate. Slight rotation can cause the problem. As I recall the screws need to have the heads drilled off as they were designed for non-repair by us do-it-yourselfers. Once the heads are drilled off the cap can be removed and the screws can then be removed with pliers and can be replaced with normal head screws. The thread is a common one.

I suggest marking the current cap location because there is nothing to align it to if you don't have a starting point. I did the entire disambly but suspect I could have fixed my problem by just removing the screws and realigning the cap. When I reassembled things it wouldn't shift but all I had to do was to rotate the cap slightly then retighten the screws and all worked just fine. Search this site for the posting. If you can't find it let met know and I will see if I can find a copy of it.

 

My grandfather had the same problem with his first gen i forget the exact year but i belive the problem was actually the auto locking hubs. I think it was from nonuse and they dry up or something. Or maybe im just completly wrong. Anybody have any idea no how wrong or right i am!?!?!?

 

I had the exact same problem.
Buy
Sharpie fine tip marker
1" of 1/4" rubber fuel line
3 8-32 1/2 round-head (phillips is better) screws.
Some Gasket compound or similar adhesive

You have to replace a $.02 cent plastic washer located on the Shift Gear limit switch. The plastic gets brittle and shatters, leaving the limit switch out of alignment, and out of commission.

Find the 4x4 Trans shifter motor. This is a small electric motor attached to the trans distribution box. The electric motor shaft is a worm gear that turns a gear in-line (off a tangent) with the motor shaft.

It was easy to remove this whole motor assembly/gear housing. DO NOT CUT ANY WIRES. There is some kind of brown sensor wire in a fitting in the transfer case. It simply pulls out (with a 'pop'.) I think it has a magnet on the end of it.

This gear is covered by a flat metal plate held by three 'security' screws. MARK THE POSITION OF THIS PLATE TO THE HOUSING!!! Clean off the road dirt, and mark a fine line next to a screw housing. (If you're really good, and have lots of light, there are fine degree markings already on the cover!)

I had to cut a notch in them with a hacksaw for a flat screwdriver. (this is the hardest part)

Once the screws are out, you can pull off this cover. You should find little pasty looking plastic chunks that have become brittle and have come off the **** on the flat side of the gear.

Cut a 1/4" - 3/16" washer of fuel line to fit over this ****. Cement in place with gasket adhesive.

Align and Replace cover, using three new screws. Paint exposed surfaces for good measure..

Ford will tell you to replace the whole motor. I found mine in perfect condition. I suspect others find the motor contacts dirty or burned, and perhaps it runs it self to death when the limit switch fails to turn it off.

The whole thing should only take an hour or so. And works like a charm.

 

I have a 91 explorer and during the winter I have to puch that button for about 5 minutes before the 4x4 is engagded.
Good luck with fixing your problem.....sorry I couldn't be of any help!
Eric

 

Let me try something here.
Do you have the truck in nuetral or park befroe you try to get it in 4 wheel?????
I thought having a push button 4x4 system meant I could push that button on the fly or just sitting in park. But thats not true with my 91 explorer. I have to stop, put it in nuetral, hit the button, then I can go have fun!
Good luck!

 

[updated:LAST EDITED ON 29-Sep-02 AT 09:56 PM (EST)]>Let me try something here.
>Do you have the truck in nuetral or park befroe you try to
>get it in 4 wheel?????
>I thought having a push button 4x4 system meant I could push
>that button on the fly or just sitting in park. But thats
>not true with my 91 explorer. I have to stop, put it in
>nuetral, hit the button, then I can go have fun!
>Good luck!

That's only for the 4X4 Low. For 4X4 High, it can be engaged on the fly.

One winter when I went to use the 4X4 on my 92 for the first time, I pressed the button and nothing happened. I heard like a clicking noise. Finally after a couple minutes, it engaged and worked fine the rest of the winter. I think if it isn't used for awhile, things get gunked up, so to speak. Hope this helps.

 

9 times out of 10 its the transfer case. Click on this link and scroll down to the transfer case section. Its a long and very detailed about how to pull it off your truck and do 1 of 4 possible fixes to it.
http://www.glue.umd.edu/~singletn/exp.html