2004 f150 4x4 problems
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Junior User
Joined: Feb 2005
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From: michigan
2004 f150 4x4 problems
I have a 04 f150 4x4 5.4L with 46,000 miles. Recently the weather turned very cold in michigan 2-5 degrees. The 4x4 will not engage all the way. I purchased this vehicle in July of 2006 with 20,000 miles on it. The truck was a lease, and I have spoken to the original owner about 2 months ago. he said the only problem he had was the problem that I am having now. He said he had it into the Ford dealer numerous times for this problem. Something to do with a selonoid on the transfer case and that the mechanic built a weather shield over it to protect it. Sounds to me like the dealer did not fix the problem correctly because it was a lease?? Now the truck has been passed on to me and it is past the factory warranty. Any suggestions would be great!! thank you!
Fleet Mechanic
Joined: Nov 2000
Posts: 1,713
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From: In my House
I'm willing to bet he meant "electric shift motor" not solenoid. This motor is what turns the gears into "4wd mode" in the transfer case, versus, the manual shifted lever. If you don't "excercise" the shift motor, it will essentially "freeze" into place. If you go underneath and tap on the motor lightly while someone turns the switch into 4wd it should work. A general rule of thumb to everyone with the electric shift 4x4, is to switch it into 4x4 once a month, just to make sure it shifts in and keeps the motor free'd up. Just my advice on things. 
Senior User
Joined: Apr 2006
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From: Springville, AL
Originally Posted by kdbbmanton
Thanks for your input, one thing that I left out was the when I put it in 4H sometimes there will be a clicking noise from the right front hub? almost like rocks in a blender.
Fleet Mechanic
Joined: Nov 2000
Posts: 1,713
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From: In my House
WOW, these 4x4 questions are really starting to come alive here in the group 
. A thing to also check out would be your IWE (integrated wheel ends) solenoid, which is mounted behind the battery. Read some of my previous posts on this issue on how the rainwater rolls right onto the top of it.
. A thing to also check out would be your IWE (integrated wheel ends) solenoid, which is mounted behind the battery. Read some of my previous posts on this issue on how the rainwater rolls right onto the top of it.
New User
Joined: Jan 2007
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Replace vaccum hoses & shift motor to make 4x4 work again
I just got my 5.4L '97 4x4 Exp. working. First I had multiple "pin hole" leaks caused by the battery acid eating into the hard vacuum tubing. Replace all the vacuum lines with "standard" vacuum hose. On the passenger-side firewall are two solenoids with a top and bottom hose. The top two connections connect directly to the front dif engagement motor. The "outboard (left) connection on the firewall corresponds with the outboard(left) position on the front dif motor, and then the inboard goes with the inboard. The bottom connections on the solenoids connect behind the battery and battery box into two vacuum bottles. Do yourself a favor and draw a diagram so you can follow how to reconnect all the lines correctly. Once this is done, you MAY be finished. Turns out I also needed to change the 4x4 shift motor. That is located on the back side of the transfer case right next to the fuel filter. I ordered a new one on-line, genuine Ford, paid $170 with shipping. The new part - YL1Z-7G360-AB, has a GREY motor cover. The GREY replaces the BLUE cover. The BLUE motor had many issues, maybe the one you are experiencing now. Anyway to change out the old motor to the new one. I took a digital picture of the back side of the wiring harness so I could ensure I rewired the new motor correctly. The motor itself is very easy to remove, just four bolts. The hard thing is pulling out the old wires from the three sensors in the transmission that need to go into the new plug. When you get the NEW 4x4 shift motor, look at the plug. Then go under your truck and pull your old plug. In it you will see a RED retaining plug. Use needle nose pliers and pull the Red thing straight out. After that go into the face of the plug with a small sharp pick, I used a dental scraper, and press near the face of the wires, you will see a plastic retaining finger holding the wire in place. Move that plastic finger slightly and then pull the wire out the back of the plug. Remove all the old wires, and push them into the new plug. Push the old RED retainer into the face of the new plug and you are ready to connect the male and female plugs and install the new motor. I put a small bead of RTV sealant on the motor housing prior to installing it. Good luck! ffice
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Last edited by ShadeTreeRepair; Jan 31, 2007 at 08:22 AM.
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Fleet Mechanic
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From: In my House
I'm not sure the 97 F Series uses the same T-case though. I believe the Espedition also has the tcase that has AWD option.
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I had my truck at the dealer last week for the same exact thing. The transfer case was engaging, but the front hubs were not. I also had the clicking as you described at the front hubs.
They replaced the solenoid. We had snow last night, and my 4wd is now working. There have been several other threads related to this and the solenoid.
If needed, I can get you a part# which was replaced. I have the receipt in my vehicle. Yours is an '04, and mine is an '05. Likely the same part#.
They replaced the solenoid. We had snow last night, and my 4wd is now working. There have been several other threads related to this and the solenoid.
If needed, I can get you a part# which was replaced. I have the receipt in my vehicle. Yours is an '04, and mine is an '05. Likely the same part#.
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Joined: Jan 2007
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Originally Posted by rpxr400
I had my truck at the dealer last week for the same exact thing. The transfer case was engaging, but the front hubs were not. I also had the clicking as you described at the front hubs.
They replaced the solenoid. We had snow last night, and my 4wd is now working. There have been several other threads related to this and the solenoid.
If needed, I can get you a part# which was replaced. I have the receipt in my vehicle. Yours is an '04, and mine is an '05. Likely the same part#.
They replaced the solenoid. We had snow last night, and my 4wd is now working. There have been several other threads related to this and the solenoid.
If needed, I can get you a part# which was replaced. I have the receipt in my vehicle. Yours is an '04, and mine is an '05. Likely the same part#.
Junior User
Joined: Nov 2003
Posts: 84
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From: Winnipeg
Mine is in shop as I write. Used term solenoid also but did not cure peroblem. Took transfercase off and found something wierd with a "partial piece of a brazed spring". I have 56000K on mine and they grilled me on having the case worked on by an independent mechanic. Right, I ma on warranty so I paid to have someone remove the spring and braze it. Logic set in. So I phoned the salesman that sold me the truck and he said all Ford 150's are like that. However, the dearship the truck is at says "Bull".
Seems to me that you have my problem, crappy parts. Anyone else had this - would like to know who is right.
Seems to me that you have my problem, crappy parts. Anyone else had this - would like to know who is right.
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