It's snow season and 4WD is great. The 4WD in our '02 Explorer worked fine last week but tonight (2" of snow) it simply wouldn't engage. The indicator lights on the dash buttons stayed dark too. No 4WHi, Auto or Low. I'll call our local dealer in the morning but... any thoughts?

 

The exact same thing happened to me yesterday. Does anyone have a suggestions?

 

I just got a call back from my local Ford dealer. There's a 4x4 control module behind the dash, near the glove box that went T/U. Easy to get to but over $300 for the module. $60 for labor (so it must be real easy). He said that although it's not real common, this is the second in two weeks. Last week they had to replace one on a Ranger. We'll have the Explorer back this afternoon. We're supposed to get about a foot of snow tonight so the wife will be happy to have her Explorer back. My '03 Expy sits in the garage next to her Explorer. My '94 Bronco is out in the barn, for sale. Kind of a Ford family.

 

When that happens on the 2002s it almost always turns out to be a bad 4X4 Control Module. It is located right behind the glovebox after you squeeze the sides together and allow it to drop down out of the way. It's the black retangular box right in the middle of the opening and has a label on that says 4X4CM. You need a new one of them and the best place to get one is directfordparts which is linked at the left here. They have sold a ton of these and will make sure you get an updated module, and it will be about 40-50% cheaper than your local dealer. I got mine there 2 years ago for $155 including shipping.

Ford made several modules for the 2002s depending on build date and trim level, so make sure you use your VIN when you order the new one. Also unhook the battery ground clamp before you snap the connectors onto the new one. Good luck.

edit: we must have been typing at the same time chuter. Sorry I didn't see your original post - might have saved you some bucks. It's a real easy job.

 

rrgone: Yup, my local dealer already has the part on the road to him. They're a small, rural dealer and good friends. He thought about trying to get aftermarket or "used but nice" but since it's for my wife he figured he'd rather have me spend the extra $ than wait through the snow storm and her her mad at him. Smart guy.
Hopefully mjh9232 will see your post and be able to save some $.
Merry Christmas.

 

Had a bad run of 4wd control modules in 02' and 03'. Our 03' had 4wd problems and the third dealer we took it to finally figured out the 4wd control module was bad. I believe there is a TSB out on it and changing the transfer case fluid is recommended but IMO is just another way to wring $$$ from you. Ford knows they had a bad batch but of course they did nothing to make it right with the customer.

 

Before you spend money on something, its always worth laying under there and giving the t-case shift motor a few whacks with a hammer. I've needed to do that twice to my '94 Explorer in the 8 years I've had it. The symptoms are... I hit the 4x4 switch, I hear some clicking under the vehicle, then nothing. Then whack the motor with a hammer and it engages in the next try or two.

I've found that remembering to engage the 4x4 a few times a month all year round has all but eliminated any 4x4 engagement problems with mine.

 

Just as a note,,I changed the transfer case fluid on my 04' Explorer,,,had 37k miles on it,,,and the fluid that came out was rather Dark,,alot darker then the new Mercon that went in it,,,,and it only take's 1.5 qts to start coming back out the fill plug hole.

There is an auto clutch in those Explorer T-cases,,,,,The darker fluid prob was clutch material.

 

That makes sense with the T-case. Dealer charged around $450 for the module and fluid change. After finding out what the module alone cost.....its a sore subject for me.