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The AWD light on my 1992 flashes 9 times between pauses. This happens after the vehicle has been driven about 20 miles on the highway. Can anyone tell me what this indicates?
The 9 flash code means: Mechanical problem that allows clutch plates to slip during clutch engagement (or faulty sensor output signal) this is directly from the Ford Service Manual. I would check the sensor plugs and the E-4WD module plugs first before going somewhere to have the mechanical part checked out. There are 2 sensors on top of the transfer case and another one I believe around the same area for the tranfer case itself. I would unplug them and then plug them back in to make sure of good contact. Check the 2 sensors out visually to make sure they look OK (No broken wires, dirty) After this unplug and replug the E-4WD module (computer) it is under the drivers seat. Also make sure it is slid on the seat rail and has not been kicked down. When you look under the seat you will see what I mean. You will also need a Ford Service Manual to work on the van. I purchased mine on disc off ebay for 15 bucks well worth it. Good Luck
You may want to also check the sensor on the rear differential as well. These use a strong magnet to generate signals from the exciter ring. The magnet will extract metal wear particles from the lubrication fluid and foul the signal. Since they are on top, they collect a lot of dirt and gunk, clean well before pulling it out to check.