I cut CM output, not the power supply and got no 12V on output, on coil only. else MOSFET inside CM may be damaged.

 

So it's been 2 years since I swapped out my T-Case. The old one has been sitting under my work bench ever since. Few weeks ago I took it apart to look inside and this is what I had found.



It seems that the electromagnet got fried. Still was drawing 3 amps but just did not create a magnetic field. I guess it shorted out.




I am not gonna bother to put it back together.

 

Occasionally I'll look at a bookmarked website that specializes in obsolete Ford parts and I see they still have a brand new factory Aerostar transfer case that fits the '92-'97 models for $495. I'm tempted to buy it, just because I MIGHT someday own an AWD Aerostar, but then reality wins out and I can't have that thing taking up space in the garage for years at a time.
Glad yours is still working.

 

Hey, DMTR, Thanks! for posting the followup. It's always nice to know the "end of the story".

I wonder why the coil fried?

 

Holy macaroni! Almost 3 years went by since the last post.
It's nice to see that my thread is the most viewed one in this forum.
Hurray!

 

Happy new year!!!!!