I have a 1998 EB with 3 settings for the 4X4, Auto, 4X4 High and 4X4 Low. The 4X4 High and 4X4 Low lights on the dash flash 5 to 6 times every 2 minutes. If you turn the dial to 4X4 High, the indicator light does not light and 4X4 does not engage. It does not automatically go into 4X4 when the rear tires spin while in Auto mode either.
I am thinking the consistent flashing 5 to 6 times must be some kind of code. Local Ford dealer says it must be some electrical issue and to bring it in. I think they just want my money to diagnose it. I suspect it is prob just some solenoid that I could replace myself, am I right?

 

You have an issue with the shift motor going out of sync, probably needs to be cleaned and the stop bumper relaced. you might try a "temp" fix by disconnecting battery and reconnect in 5min, this lets the puter relearn the position of the cam, remember if this works it is only a temp fix...

 

I will check it out. It is difficult to clean the shift motor and replace the stop bumper? Is the stop bumper expensive?

 

I had the same problem on my 98 about a year ago. The first thing you can try is to remove the two drive shaft speed sensors from the t-case and wipe them off. They are two magnetic sensors that mount in two places on the t-case. One is mounted kind of behind the shift motor and you have to remove the motor to get to it. The other is mounted just to the right of the shift motor. I believe it is cylindrical in shape and is mounted with a 10mm bolt. It should have two to three wires leading to the shift motor. I cleaned the one for the rear driveshaft speed sensor and my code cleared. I ended up later replacing the sensor and bought a rebuilt shift motor at rockauto.com for about $65.00. I changed the t-case fluid to synthetic and have had no problems since.

If you end up replacing the sensors dont cut the brown wire that leads from the t-case to the harness. If you open the harness connector you can remove the red plastic insert and that releases all the wires so you can easily replace the sensors. I may have part numbers written down somewhere for the sensors. If you need them let me know and I'll see if I can find them.

 

I have a 1997 EXP Sport. Similiar issue. 5 speed, Control Trac with same dash lights and control switch...
------- 4X4 --------
AUTO HI LO
I installed an overhauled Tranfer Case from the Vendor Ford Dealers use, appx 6,000 miles ago and 2 years ago. I had no problem at all until recently. On rare, RARE occasions, the 4X4 lights will flicker while in AUTO mode. Operation is normal when it occurs, nothing unusual occurs and it goes away as fast as it came.

A couple of months ago, a new symptom appeared. Again in AUTO mode, at very low speeds and only when going into 1st or Reverse and always with wheels cut fairly sharply, you can hear what sounds and feels like the 4X4 trying to engage. It only occurs with cluth fully depressed, and as you let out the clutch, you can hear the the transfer case working to engage (as you are still rolling), followed by a solid clunk and lurch, if you continue to let the cluth out. The lights on the dash do not come on when this occurs. This is very hard to get to repeat. I obviosly now, keep cluth in, stop and shift to neutral, whenever I sense this. This immediately stops the action that is occuring. It may not repeat again for another week or so.

No codes are present. Transfer case is fully serviced. All tires are new with equal pressures. The cluth control ,master cyclnder is fully serviced and works quitely and smoothly. I really do not suspect this transfer case, with such low miles since overhaul, although I am aware it cannto be ruled out completely. The 4X4 feature works fine and lights react normal when using 4X4 feature. I have never used the 4X4 feature, except for when I installed the overhauled unit, and now for troubleshooting, and only in my driveway. I basically baby this EXP.

The comments on the shift motor and possible syncing problems, and the speed sensors from AQUANAUT20 are what caught my eye. I am only aware of 2 speed sensors on my 1997..one in Transfer Case and one in the Rear Axle housing. I installed a new one in Trasfer case, and I have proven the old one is fine. I will look for the other sensors mentioned. I haven't replaced the one on in the rear axle housing. If I recall, I had to reuse my shift motor when I installed the overhauled TC.

Any additiional info anyone may provide would be greatly appreciated. THX ALL!

 

OK Guys, have been away for a while

Read this article and follow the steps to correcting the T/C shift problems

http://members.aol.com/racsan99x/Fix...ansferCase.doc

 

WHERE ARE THOSE SPEED SENSORS??...look here

I found a pic I took of my borg warner 4405 as removed from my 1997 exp sport 4x4, 5 sp manual, with all the accessories removed. I tried to cut and paste it here, but no success.

Anyway, to my supriseIi could see there are TWO speed sensors pads located on the rear side of case! One is easily visable from under the truck. It is located in just under the rear drive shaft output flange at appx 7 o'clock as viewed from rear.

The other, which I was not aware of, is very hard to see from underneath truck. It is located just above the shift motor! The shift motor blocks your view.

I see a lot a post talking about the sensor located in the rear axle. From what I have read and understand, this 3rd sensor is for ABS only! The 2 sensors that read the front and rear axles speeds are the 2 mentioned above...at least that is what I see on my 1997 Exp 4x4 brog warner 4405 with manual 5 speed tranny.

Hope this helps some of you. I have replaced the lower one on my Exp and the flashing lights and occasion uncommanded engagement into 4wd (with dash switch in AUTO - 2wd) have not changed. I will now replace the upper one. Will advise.

 

www.therangerstation.com
choose tech library
then down the left side see xfr case motor
step by step to clean the shift motor

 

Thanks!, I will check it out. I might as well pull the shift motor and perform the clean steps. This will give me better acccess to the speed sensor located just above it. I suspect it is acting up and/or has intermmittent electrical contact,

 

Sorry Guys, did not desert you. Back from ICU (2weeks) forced vacation. Now bedrest for another month (min) before i can get my nails dirty again, LOL, we shall see how long that lasts. I will try to follow the tread,