4x4 HELP - Ford Powerstroke Diesel Forum

 
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post #1 of 6 Old 11-11-2012, 07:06 AM Thread Starter
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4x4 HELP

My 4wd has left me stranded twice in the last month. It just doesn't engage. The light reads accurately and I have tried both auto and manual lock on the hubs. I think It is not engaging in the transfer case. Both times I was able toget it to engage after the fact by driving and switching to 4wd but for some reason it doesn't engage when sitting still. It also does not stay engaged but I'm not sure when it disengages itself(possibly when I shut the truck off)

Any help would be appreciated. I'm leaning towards vacuum or this electric motor that engages the transfer case but I do not fully understand the theory of operation.

Thanks,
Chris

Christopher Cerrone

-2005 F250 Lariat 6.0l CC, SB, ARP Headstuds, EGR Delete, Turboback MBRP SS 4" Offroad Exhaust, AFE Stage 2, Rancho Shocks, Rancho Dual Steering Stabilizer, Mag-Hytec Diff Covers, Mag-Hytec Trans Pan, Issopro Gauges, 20" Black Rockstars w/ 35" Nitto Trail Grapplers, 2.5" Ready Lift Leveling kit, Bushwacker "Pocket Style" Flares, N-Fab 6-step Nerf Bars, Edge Insight CTS Monitor, SCT X3 w/ Innovative tunes, Recon Tails, Recon Third Brake Light, Recon Mirror Lenses.
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post #2 of 6 Old 11-13-2012, 05:07 PM Thread Starter
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No one knows the 4x4 theory of operation and can offer me some insight? I would really appreciate it.

Christopher Cerrone

-2005 F250 Lariat 6.0l CC, SB, ARP Headstuds, EGR Delete, Turboback MBRP SS 4" Offroad Exhaust, AFE Stage 2, Rancho Shocks, Rancho Dual Steering Stabilizer, Mag-Hytec Diff Covers, Mag-Hytec Trans Pan, Issopro Gauges, 20" Black Rockstars w/ 35" Nitto Trail Grapplers, 2.5" Ready Lift Leveling kit, Bushwacker "Pocket Style" Flares, N-Fab 6-step Nerf Bars, Edge Insight CTS Monitor, SCT X3 w/ Innovative tunes, Recon Tails, Recon Third Brake Light, Recon Mirror Lenses.
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post #3 of 6 Old 11-13-2012, 05:27 PM
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Start simple--is the front driveshaft turning the times that you think it's not engaging? If so, check all your vacuum lines and seals.

If not, pull the electric motor off of the transfer case and see where the selector is pointing. If it's out of range, the stop bushing in the motor may have rotted out and can be repaired with some fuel line.

2005 Excursion Limited 6.0L 2wd
Atlas 40, Bulletproof EGR cooler, coolant filter, 6.4L banjos, Cat coolant, Gogo direct solenoid, 7.3 fan clutch. Otherwise, all stock.
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post #4 of 6 Old 11-13-2012, 05:30 PM Thread Starter
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Thanks for the tips. I'll start there.

Christopher Cerrone

-2005 F250 Lariat 6.0l CC, SB, ARP Headstuds, EGR Delete, Turboback MBRP SS 4" Offroad Exhaust, AFE Stage 2, Rancho Shocks, Rancho Dual Steering Stabilizer, Mag-Hytec Diff Covers, Mag-Hytec Trans Pan, Issopro Gauges, 20" Black Rockstars w/ 35" Nitto Trail Grapplers, 2.5" Ready Lift Leveling kit, Bushwacker "Pocket Style" Flares, N-Fab 6-step Nerf Bars, Edge Insight CTS Monitor, SCT X3 w/ Innovative tunes, Recon Tails, Recon Third Brake Light, Recon Mirror Lenses.
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post #5 of 6 Old 11-13-2012, 05:33 PM
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If it's anything like the 1356 cases, here are some pictures I took a long time ago:

http://fullsizebronco.com/forum/showthread.php?t=30512

2005 Excursion Limited 6.0L 2wd
Atlas 40, Bulletproof EGR cooler, coolant filter, 6.4L banjos, Cat coolant, Gogo direct solenoid, 7.3 fan clutch. Otherwise, all stock.
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post #6 of 6 Old 11-15-2012, 01:10 PM
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There are 3 things that must happen to engage and get the 4x4 light. Switch position, vacuum/hub lock, and engagement via shift motor position. It will try for about 20-30 seconds and time out if it can't engage. It is quite common for the shift motor to go bad. Look on eBay for a new one. Try shifting from a stop, sometimes the ESOF will work better 10 mph or less. The older they are, the more likely to fail or work slowly, especially in really cold weather.

The next problem is the mechanism in the transfer case being dirty or worn. You could try to flush the T/C with a cleaner then put in new fluid.

Frank
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Stiction Problems - Fix it yourself! - http://www.powerstroke.org/forum/gen...ml#post4509754
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