ok great i will do that today. thanks

 

Can the heater core going out and blowing antifreeze all over the compartment where the 4WD Control Module sits cause it to short out and quit working?

 

I've got the 4wd High/low lights flashing once in a while. I cannot use 4wd switch when this happens. I turn the truck off and on again and everything works again. I have no problems with any other electronics. I just replaced the T-case fluid this morning. I was going to look at the Hall sensors and harnesses when I noticed this online TSB from Ford.

Ford TSB

97-21-15 OCT 97 Transfer Case - Shudder/Binding In Tight Turns

• Shudder Or Binding Sensation - In Tight Turns While Vehicle Is In 4x4 Auto Mode - Vehicles Built Through April 1997.

• Transfer Case - Shudder/Binding Sensation In Tight Turns While Vehicle Is In 4x4 Auto Mode - Vehicles Built Through April 1997.

My vehicle fits this build date. I need to check the part number on the GEM but I have a feeling its this calibration problem.

LIGHT TRUCK:
1995-97 EXPLORER

ISSUE:
A shudder or binding sensation in tight turns while in 4X4 Auto Mode may be experienced on some vehicles. The shudder is due to a high torque output from the clutch in some transfer cases.

ACTION:
Re-calibrate the existing Generic Electronic Module (GEM) if the GEM is identified with engineering part number F77B-14B205-BB. The revised calibration commands a lower torque which allows the transfer case clutch to engage smoother so shudder or binding should not result.

 

Hi, i tried the grease and working the conections but no luck. I changed the 4x4 module and i am getting the same exact thing as before i changed it. 4x lights light up when truck starts, when i turn switch to 4x i here the module click but no 4x. Any ideas where to tun next...

thank you
Al

 

My '04 lost 4x4auto & hi/lo when the right front ABS sensor went bad. Figured it out with a Snap-On scanner hooked up driving and the sensor would short when I would turn left.

 

First of all wanted to say THANK YOU to everyone who has posted in this thread, it took me a couple of hours (slacking off at work) to make my way through, huge amount of useful information. Gratitude.

I got my '03 Explorer Limited 4.6L a bit over a month ago and have been having 4WD issues with it... posted it in it's own thread : https://www.ford-trucks.com/forums/1...-explorer.html

The short story is that the 4high and 4low illuminate on the cluster during startup, however when I push the buttons nothing happens. That is, unless I do it WHILE I'm starting the truck (so ignition on press button then keep turning until the engine turns over), then 4high comes on. However, I'm not convinced it's actually engaged but haven't had a chance to really test it yet (back end kicks out on slippery roads).

Just tried unplugging the module then plugging it back in, but same problem.

I'm suspecting it's the shift motor itself as there was some damage near the transfer case (heat shield broken, small crack in the case near the drain hole) but want to be a little more certain before I silver bullet the problem and shotgun the part, especially because it's cold and snowy here and working on the truck is difficult.

Any of the brilliant minds in this thread have a thought to add to it? More details in my thread linked above... THANKS AGAIN

 

I have a 2002 Sport Trac, the 4X4 lights on the dash just suddenly went out. Luckly, I had just switched back to 2 wheel high. I went to use it about an hour later and nothing. No lights on the dash, Checked the fuses, all good just quit working. According to my vin number, my vehicle takes the TM-96 and Ford wants $387.00 for it. Looking for a cheaper source.

 

Is that module still available?

 

I guess this is a cash cow for someone,just loosing power to the unit calls for replacement, ounds like a preconceived problem that was invented.
Is there anyway to eliminate this component and have a more reliable way to get the transfer case to engage?

 

instead of starting a new thread, I figured I'd post this in here

I just bought an 02 limited v8, no 4x4, no lights (cluster ones are out, console buttons are lit when headlights are on)...I replaced an 02 xlt v6 with the limited... The 4x4 worked on the xlt - can I use the module from the xlt and pop it into the limited? XLT is going to the junkyard anyways

 

Are you sure the 02 V8 has 4x4 rather than AWD? Are the console buttons you are referring to for the transfer case, or just console lights in general? If AWD, you won't need the module from the XLT, but it might be worth salvaging anyway since it appears others may be in need of the module.

-Rod

 

yeah, it's not full time AWD. The console lights I'm referring to are on the right hand side of the radio unit they are labeled

Auto 4x4
Hi 4x4
Lo 4x4

When I have the headlights on those buttons are illuminated - as is the rest of the dash

Each one can be pushed and for the 4x4 hi and lo a corresponding light should light up on the cluster - it's normally in 4x4 auto; there is no light on the cluster for that

this is what it looks like - the 4x4 buttons are on the right hand side

 

I would suggest you grab the module and, if you can get away with it, the transfer case servo, from the truck headed for salvage. The compare the numbers from them to the numbers on the module for your V8 that don't seem to be working. If the numbers are the same, you should be able to swap them out.

I'll have to check the service manual to see if any programming is required. I doubt it....

-Rod

 

So I took the module from the XLT and popped it into the Limited - Auto and 4WD High work...when I push the 4WD Low the button blinks for 5/6 seconds, then doesn't engage

The p/n from the XLT was 2C54-7H473-BD, p/n for the Limited was 2C54-7H473-BE....not sure if going from the D to E last letter would affect that, but I'm going to dig around the junkyard for one ending in E just to know for sure its the same one

Thanks everyone

 

Were you completely stopped with the transmission in Neutral when trying to engage 4x4 Low? When shifting into or out of Low range, the 4WD control module requires that the vehicle speed is less than 5 km/h (3 mph), the brake is applied, and the transmission is in Neutral.

From the factory service manual:
CHECK THE LOW RANGE INDICATOR FOR ON IN 4X4 LOW
-Apply and hold the brake pedal.
-Shift the transmission to NEUTRAL.
-Listen for shift motor operation.
-Hold the shift conditions for 20 seconds. (The system will use up to five cycles of shift attempts trying to engage 4X4 LOW.)

If that doesn't work, then the manual recommends the following:

• Shift the transmission to REVERSE and back the vehicle up 3.0 meters (10 feet) to relieve driveline windup and stop.

-Drive the vehicle forward for 3.0 meters (10 feet) and stop.
-Apply the brake pedal and hold.
-Shift the transmission to NEUTRAL.
-Observe the 4WD LOW indicator.

-Rod