How Embarassing
Elder User
Joined: Aug 2007
Posts: 914
Likes: 1
From: Saskatoon, SK, CA
What Krewat said and does the 4X4 switch have lights on (meaning when the dash lights are on). This happened to mine and all that was wrong was that the connection behind the switch on the dash was loose. Pushed it in and it worked fine. Start simple and move to bigger problems like T-case motor. Also check connections to the t-case motor. And, as others suggested, move hub selector to manual and try it again. Just keep troubleshooting.
Senior User
Joined: May 2002
Posts: 495
Likes: 0
Do you hear anything when you press the switch?
On my 93 Bronco I could press the switch to go into 4WH and I would hear some "clicking noises" under the dash each time I would press the button. I believe it was the solenoid's relay energizing and de-energizing. This is normal, BTW.
But I wouldn't hear or feel the transfer case engage.
There is a solenoid on the backside of the transfer case and it engages and disengages the gear set. Mine would "stick" and not engage. It was worse when the weather got cold.
While someone is pressing the 4x4 button, crawl under the truck and lightly tap the drive mechanism of the solenoid with a hammer. Don't whack it hard, it's just cast metal case. But just enough to vibrate or shock the sticking plunger inside.
Once it engages, drive it around a bit to build some heat into the transfer case and cycle the unit 3 or 4 times to loosen it up.
Once that happenes remember to engage 4x4 several times a year in an attempt to keep it loose.
My experience ... HTH
On my 93 Bronco I could press the switch to go into 4WH and I would hear some "clicking noises" under the dash each time I would press the button. I believe it was the solenoid's relay energizing and de-energizing. This is normal, BTW.
But I wouldn't hear or feel the transfer case engage.
There is a solenoid on the backside of the transfer case and it engages and disengages the gear set. Mine would "stick" and not engage. It was worse when the weather got cold.
While someone is pressing the 4x4 button, crawl under the truck and lightly tap the drive mechanism of the solenoid with a hammer. Don't whack it hard, it's just cast metal case. But just enough to vibrate or shock the sticking plunger inside.
Once it engages, drive it around a bit to build some heat into the transfer case and cycle the unit 3 or 4 times to loosen it up.
Once that happenes remember to engage 4x4 several times a year in an attempt to keep it loose.
My experience ... HTH
Posting Guru
Joined: Jun 2004
Posts: 2,433
Likes: 1
From: Apex, N.C.
Sorry if this is a little off topic, but does the T-case in the ESOF have a physical neutral, that it is just bypassed by the solenoid, meaning that if you converted it over to a lever shift, so you could benefit by having a neutral if you wanted?
Lead Driver
Joined: Dec 2006
Posts: 7,093
Likes: 147
From: San Diego, CA
I don't know of any hubs for the SD that don't have a switch (OEM or aftermarket). They all have a manual lock.
Elder User
Joined: Oct 2008
Posts: 519
Likes: 7
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Hotshot
Joined: Jul 2003
Posts: 12,177
Likes: 40
From: Newport, WA
The manual shift T-case like yours was standard, ESOF was an option. Most will tell you the manual is the better option to have. My early 99 F250SD has ESOF.
Elder User
Joined: Oct 2008
Posts: 519
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BTW- Thumpertalk is another awesome forum! I'm on there under the same name, frequenting the Kawasaki 2-Stroke and General forums.
FTE Leadership Emeritus
Joined: Jul 2002
Posts: 42,561
Likes: 423
From: Long Island USA
If the 4x4 light comes on in the instrument cluster, that means the transfer case is actually shifting into 4x4.
Sounds like the hubs aren't locking - try locking them by hand and checking out 4x4.
If it works with the hubs locked, then start diagnosing the vacuum hubs.
Sounds like the hubs aren't locking - try locking them by hand and checking out 4x4.
If it works with the hubs locked, then start diagnosing the vacuum hubs.
More Turbo
Joined: Dec 2002
Posts: 743
Likes: 2
From: MI -- farmboy
my truck did the same thing, 1 time. NEEDED 4wd, hit the switch and nothing, no light, no clunk. After 10 or 15 minutes, it worked again.
Wonder if there is a corroded wire near the shift motor ? MAybe a dirty plug ?
I am thinking these are set up just like all fords with electric shift ? Dash switch, shift computer and shift motor ? 9 times out of 10 the shift motor has some wear or corrosion inside the gear head on the selector switch, which is normally non-repairable.
Process: Driver select 4h, computer sets go signal to shift motor, shift motor manually rotates modified shift lever on transfercase to 4h pos. If truck is equipped with vac hubs, the solenoid for the vac hubs is engaged and hubs lock onto axel shaft. If manual hubs, driver must manually engage lockouts.
Driver select 4l, computer check to see if truck in N and/or foot on brake pedal. Process continues as if 4h, but selecting 4l.
I think this setup was brought to public use in 86 on the rangers and bronco II. I worked on a lot of these, all my years of this and I only changed 1 shift computer and 1 set of switches, the switches from abuse, the owner punched the switches because the shift motor did not work.
Wonder if there is a corroded wire near the shift motor ? MAybe a dirty plug ?
I am thinking these are set up just like all fords with electric shift ? Dash switch, shift computer and shift motor ? 9 times out of 10 the shift motor has some wear or corrosion inside the gear head on the selector switch, which is normally non-repairable.
Process: Driver select 4h, computer sets go signal to shift motor, shift motor manually rotates modified shift lever on transfercase to 4h pos. If truck is equipped with vac hubs, the solenoid for the vac hubs is engaged and hubs lock onto axel shaft. If manual hubs, driver must manually engage lockouts.
Driver select 4l, computer check to see if truck in N and/or foot on brake pedal. Process continues as if 4h, but selecting 4l.
I think this setup was brought to public use in 86 on the rangers and bronco II. I worked on a lot of these, all my years of this and I only changed 1 shift computer and 1 set of switches, the switches from abuse, the owner punched the switches because the shift motor did not work.
Posting Guru
Joined: Jan 2003
Posts: 2,181
Likes: 3
From: Eastern CT.
A buddy of mine had an 04' F-350 Harley-Davidson, 4x4,,and you could not see any hubs with what was thought to be the stock wheels on that truck !! I thought this was kinda strange,,,I am assuming that the center caps were infact hidding the Auto/Manual hubs,,,he said his 4x4 worked but I really cant recall seeing another 4x4 SuperDuty with hubs you cant see ! Anybody else ever see one ??,,,,,,,Check your center caps,,may be hidding your hubs.
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