Yes it makes sense and could be why the module was removed in the first place. If your Aero was like the one I mentioned above in full 4X4 all the time then when it gets dry out it will hop around like a bunny. When the system is working properly, the front gets approximately 30% of the driving power and the rear gets the rest. As the module and computer(PCM) see slippage in the rear it sends more power to the front until it is approximately 50/50. if the system has failed and is now in the 50/50 mode you'll be able to get around great right now but when it is dry it will hop and bind. If this is the case, you can install a switch and mount it to the side of the seat bracket that you can use to turn off the power to the module and turn off the electronic 4X4 system making your Aerostar a true 4X2 then when you need it just turn the switch on and wala 4X4.

 

Hi X.L.R.8.

If you go under the van and look at the wiring harness, there are three connectors. Two go to the front and rear speed sensors, and one goes to the clutch coil. Go the the thread started by canders_00 "Help with transfer case" and there is a step-by-step instruction on how to trouble shoot your transfer case.

If the clutch coil is bad, that can be replaced, but you would have to tear it apart, which is actually pretty easy. There is no need for any special tools, except for one you might have to make yourself to open the front output yoke.

 

Ok I'm feeling brave and know there are a few forum users who may get a laugh at my expense, i'm going to put the rear up in a jack and see if the front has drive, then I'll do the same with the module plugged up and then again with the jumpers insitu, don't worry, it will be pointing into 8 acres of snow so if by some reason it jumps forward it will only be a trouser soiling moment rather than a repair moment.

 

OK I'm back no broken bones but a successful trip to the garage, it didn't have 4WD without the module, or with, but jumping the pins 14 to 8 and 13 to 7 I now have 4WD, I'm guessing there's a short in the system because the circuit failed test F3, it works with the jumpers in place so I'm going to guess if I take an earth contact and put a switch in line to pin 13 this will give me switched power to the 4WD system, or if I'm creative I could take a feed from 8 and via a switch to 14 and 4, that way the light will come on when I have the 4WD on? unless it's an earth powered switch.

 

Just take the plug off the module completely, ground pin 13 and put a push-button switch between 8 and 14. Then you have 4WD everytime you depress the button. But that switch should be a pretty heavy duty switch. I wouldn't put anything less than 10A capacity there.

 

I wanterd to know when the 4WD was on, however I did the connection as I planned and the light came on for a while and then when I did a tight turn I got the wheel hop (I thought a UJ had gone as I have never had that before) and the light went out, never to come back on, I used a 15 amp circuit breaker type fuse to make the switch as I had a load of them laying about and if something went wrong I know it would trip, I hadn't expected the light to go though, I'll investigate further one day, for now I have 4WD on a switch and new front brakes, what more could one ask for, air con that works, I'll save that for summer, I know it's the compressor as the bearings make a horid sound when it's on adn the system does not develop any pressure, in the mean time I'll jsut count my blessings that last year I didn't put it in a ditch thinking it was 4WD, I drove across the field with a good 9 inches of snow and it ploughed it's way through quite happily, it's only slightly better on Ice but with all 4 wheels spinning 400WD would make no difference. thanks for everyone's time and patience, I was thinkiong about becoming a member just to say thanks but for some reason that part of the site does not liek my old mac and displays a frozen screen and error pop-up's, I'll fire the wintel up later and rectify the situation as without the site I'd probably be off to having my trousers pulled down by a dealer. Once again thanks.

 

your most welcome, I glad that I was a help and atleast you wont have to worry about any repairs until the ground thaws. Take care and drive sane!