1995 150, XLT, 5.8l, 180XXX miles
Last repair was 6 months ago, fluid changes: engine, tranny, transfer case, and differential oil changes
- Novice at repairs

For a few years the 4x4 push switch light on the dash would stay on, even after it was pressed to turn 4x4 off. It would only turn off and stay off after key was out. No biggie.

The other day after pushing 4x4 off the (I believe) transfer case motor began making a fast clicking sound for a few seconds, then stopped. Ok...

Later, after another 4x4 off, the clicking sound returned but lasted for many minutes, even after engine off and key out. It was a very rapid ticking, sounded like metal on metal, and changed in tempo somewhat. After that nothing in the 4x4 system worked.

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Control Module Self-Test: OK.

5 Wire Connector Test: Ohm meter between terminals 1 & 2, push 4x4 button: <50 ohms (33, I believe?). OK. Ohm meter between terminals 1 & 3, push LOW button: <50 ohms. OK.

Jumped wire between terminal 4 and ground. Ignition to Run. LOW light illuminated. OK. Jumped 5 to ground, 4X4 light also illuminated. OK.

8-Wire Pigtail Connector Test: No voltage present at terminal 8 with engine off. BAD. No voltage present at terminal 7 with ignition on. BAD. Should show voltage at both terminals. Possible user error?

Ohm meter on terminal 1, shift transmission to Neutral, was <50 ohms. OK. Measured resistance between terminals 2 & 3, was 270 ohms. OK. Speed sensor in transfer case OK.

Have not tested Main Feed Connector inside center console/instrument panel. Pain in the *** to access, rather not if I don’t have to. Haven’t tested 4x4 switch. Haven’t tested motor or checked for power going to motor.

No blown fuses. Relays don’t click anymore so unsure of status.

Tried hitting the motor with a hammer.

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I would imagine if I tested for power going to the TC motor I wouldn’t see any, because when I press the 4x4 button nothing happens at all. So clearly it’s not getting power. I feel my next step is taking the dash apart to get to the GEM and testing that? No experience there at all.

Thanks everyone. This is a toughie.

I would highly prefer a manual shift. Is there a specific website or video that helped with the process? I’ll start learning about that tonight and hopefully it won’t be too bad bypassing all these electronics.

edit:
Okay, so I just saw “The Shiftster”. Very ****ing interesting, man. Very interesting. I really hate vehicle electronics and I’m really not in the mood to chase down this electrical issue over the next few days, so I’m really thinking about this product. I only go into 4x4 a few times a year, so crawling under the truck to rotate the **** isn’t a big deal.

Though it got me wondering: if all you need to go from 2x into 4x is to rotate the spindle that goes into the transfer case, and nothing else (apart from being in neutral and locking your hubs), then surely a shifting lever that goes from the TC spindle and into the cab could be fabricated, right? It would a hassle to do and build, not economical at all, but besides doing a manual transfer case swap it would be the next easiest option, after The Shiftster.