99 ford expy problem - the instrument panel 4x4 light does not come on at all - even when starting the car or in test mode, the 4x4 switch light is also out, and obviously the expy is not shifting into 4H. I've searched and read the forums and will be checking the vacuum hoses and/or replacing the transfer shift motor. Before I replace the motor, could it be a fuse or wiring issue - because both lights are out? When I change the switch from A4wd to 4H, I do hear a relay clicking under the dash to the right of the instrument panel but then nothing happens. Oh great and wise Expy wizards, what do you think?

 

As with any potential electrical problem, check the fuses first. Your owners manual shows what each fuse is for. If you don't have your owners manual it can be found here. https://www.fleet.ford.com/maintenan...ls/default.asp On my 99 when you first turn on the key and lamp test mode of all the instrument cluster lamps come on, the only one that lights up as far as the 4x4 lamps is the low range light, however when it's switched to, and engaged in 4 high, the 4x4 light turns on, and when it's in 4 low, both the 4x4 light and the low range lights are on. One way to determine if your shift motor is operating is with the key on but with the engine not running and your window open, put your foot on the brake, then put it in neutral. Keeping your foot on the brake, turn the switch to 4 low and listen, you should hear the shift motor run underneath the vehicle. Then switch it back to A4WD, and you should hear the shift motor run again. I'd say if you're hearing the relay clicking but not the shift motor operate, I'd suspect your shift motor is bad as it's not uncommon for these to go bad. As far as your switch light, it's probably burned out. Ford no longer makes the replacement lamps for these, however I've heard that you can replace the bulb with these lamps from Radio Shack http://www.radioshack.com/product/in...ductId=2103780 There's also a thread on this forum that shows some replacing them with LED's. The price of a shift motor can run anywhere fro $60 for a rebuilt to $150 at the dealer. I've seen brand new ones on ebay however for around $90 with a lifetime guarantee. This is what the shift motor looks like, it's mounted to the back of the transfer case. Replacing this will require the swapping of about 4 wires from the old connector to the new one.

 

Madsonp - Thanks for the reply. I did check the fuses and everything seemed fine. I also check the resistance of the 4x4 selector switch and it was fine. I just checked to see if the transfer motor kicked on and it did not. Looks like I will be ordering one today. Also, thanks for the tip to fixing the burned out switch light.

 

You bet, be sure to get back with us and let us know how things turn out.

 

just finished replacing the transfer motor. That did the trick. I just tested it in the snow that's pounding us here in Ohio. She handled well. Transfer motor replacement was tougher than I thought. It's a cramped space where the motor is located! Thanks for the insight madsonp!

 

I'm glad you got it fixed, thanks for letting us know.

 

one more thing...I did replace the bulb in my 4x4 switch. I used your advice and bought the bulbs from radio shack... http://www.radioshack.com/product/in...ductId=2103780

I also used http://www.cardomain.com/ride/296394/12 as a guide to removing the old bulb and replacing it with the Radio Shack one, even though I didn't change it to LED - which the guide is designed for. Again thanks for the help!

 

Great, sounds like you're good to go then. Be sure to let us know if there's anything else we can help you out with.