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I very seldom use my 2000 V-10 4X4 Excursion in 4 wd, and was surprised to see the 4X4 light on. I lost all 4wd functions, so I had the GEM scanned and the fault was found with the Transfer case motor. The Ford list price on this motor is just over 500. but the A1 Cardone rebuild from Rock Auto is around 99.00 so I tried that. Promptly after installation it blew the 30 AMP fuse for the Transfer Case Motor. Rock Auto sent a replacement, and it worked three times after installation and then it quit. The replacement motors from Dorman (134.00) are out of stock and Dorman has no idea when more will be available. I can get the Ford unit for 248.00, but wonder if anyone has any other options.
You might want to check the wiring for any extra resistance. a 30A fuse is pretty hard to blow, maybe you have wiring issues. The motor is almost identical to a window motor IIRC
I opted for the Ford Transfer Case Motor and now I can operate the 4wd, but the dash light "4 x 4" stays on when it is in 2 wd. It stays on for 4wd High and changes for 4 wd Low. Not sure what to check other than for wiring problems. The two relays check OK. The scan tool recognizes that the switch is sending the correct signal to the GEM, but we can't figure out why the light remains on. Any ideas?
Carl