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1997 Exp. Went out on the snow packed roads and noticed fornt wheels would not engage when in any 4x4 mode. The switch is not blinking. I can hear the motor engage when shifting to low. It moves slow while in low only no front wheel pull. Any Ideas where to look for the problem? Is there a common point of failure? I have a obd scan tool, vacuum gague and a multimeter. Thanks in advance for any ideas.
My 1997 Expy 4X4 would also not engage, discovered it on a hunting trip so I took it into the closest Ford Garage. They worked on it for a couple of hours and finally figured out that the vacuum lines that run down the passenger side of the engine had hit the manifold and were melted closed. There was an earlier recall to reroute the vent tube for the front axle. I think when they were in there fooling with the vent tube they may have pushed the vacuum lines against the manifold. Other than that I'm not sure how it could have happened. Anyway, you may want to at least check the lines, easy and cheap fix to splice the lines if that is the problem.
my 98 has a vacuum module on the front axle. the line previously mentioned goto it. check the vacuum with a tester. also there is a lever from the module that goes into the front diff. it can get stuck in one position as well. Mine did. I had to work it back and forth a few dozen times to get it freed up.
The vacuum line to engage the front axle runs behind the battery. Often the corrosion from the battery drips down and eats through this vacuum line. No vacuum, no front axle engagement.
Problem solved. It was the shift lever that was stuck. All the vacuum system was fine. Some spray lube and moving the lever worked. Thanks for the help!
The lever on the front differential. It is moved by the "front axle actuator" (vacuum driven). Mine has a black plastic cover over it. Finally a simple, free fix.
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