Another day, another thing went wrong....was in some wet grass so i hit the 4x4 switch on the dash of my '95 f150 for 4wd. nothing happened....no orange light, no clicking from 4x4 module. I went down to the ford dealership to see what i could find out. However, being full of younger mechanics, none of them were familiar at all with this 4x4 system. Pretty much, i was told we can throw $600 and see if that fixes the problem. I talked to my local mechanic and there is another truck in the area with the same problem but we are unsure how to go about fixing it without spending a ton of money.
**Does anybody know how to diagnose the problem as either the switch on the dash or the module? My hayes manual implies that the module has a ton of functions and it is difficult to figure out what is wrong.
**Anyone know of where i can find a procedure to diagnose the control module?
Since the switch is over $150 and the module over $300, does anybody know if i can buy the manual linkage and hook the transfer case up to shift via a lever in the cab or do i need to look into a whole new transfer case for that?
thanks

 

i would first check the motor on the case, always a problematic thing if there not used alot.

 

If not the motor, and I agree, I'd check it first, the relay. I've seen people get them from salvage and use one from an Exploder in and F-150. Much cheaper that way. Let us know what you find out.

 

thanks for the replies so far guys. i usually use the 4x4 at least 1nce a month and this is the first time ive had a problem with it. The reason i dont thinki it is the motor is i didnt hear the control module click like it normally does, this is what makes me believe its either the switch or the module itself.
Also, is there a way to tell the position of the gears in the t-case? I ask because i wonder if the last time i used 4x4, if maybe the gears only moved perhaps 90-95% of the way where they are supposed to be. This would make the truck act like its in 2x4 like normal but might give the module a confused signal.....just a thought.

 

by the "control module", do you mean the relays?

 

well, in a way, yes. Looking at my Hayes manual, the system essentially consists of the dash switch, "control module", t-case motor, and the t-case. According to the manual, the control module (which has over 20 wires running to it!) is located behind the passenger side kick panel and it regulates many things such as speed, transmission gear, t-case status (4x4 hi-lo or 2x4). The problem im finding is i dont know how to ever go about diagnosing the problem here or if its in the t-case itself or motor or what.

 

Sounds more and more like the "module". A quick way to diagnose is to actuate and listen for the "response" from the module/relay. You can search the forum and there was an identical issue last year. He used a module from an Explorer on the F-150 like I mentioned earlier, I believe. Keep up the post and advise.

 

Anyone find out what the problem was in the end ??

 

AAHHHHH. this system has gone completely crazy! So the truck was acting just fine today and i never touched the 4x4 system at all thinking id just let it go a couple days. Well i came home from work and parked the truck. 2hrs later i went out to leave again to head into town. Upon starting up the truck i hear the click from the 4x4 control module and the 4x4 light comes. This really confuses me because i havent touched the button all day!! has this thing gone completely crazy? I tried hitting the button to get it to go out of 4x4 but had no luck. (hitting the botton did nothing). so now i have a pocessed truck stuck in 4x4 and no clue as to where the problem lies.

 

This thing is still acting funny. Upon certain startups it will randomly click (the 4x4 module) and 4x4 light will come on. However, it doesnt actually engage the 4x4, it just turns the light on. Then, it will turn off again after i turn it off and start it a couple times. I tried to hit the button after if "shifted" into 4x4 but nothing happened. I think im going to try and find a replacement module because that is what seems to be acting funny