Another 4x4 problem!!!!! - Ford Powerstroke Diesel Forum
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Old 11-11-2013, 09:26 AM
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Another 4x4 problem!!!!!

Ok so I got my truck out of the shop after the bulletproofing head, studs, etc put 2200mi on it since and tried the 4x4 nothing, lights on cluster come in when starting the truck, which means it's checking itself right? And then when I physically turn the ESOTF switch, nothing happens, no clocks under the dash no 4x4 light and I'm sure no vacuum to the front hubs, because it goes in sequence... Looked at a lot of posts about the GEM but they say my 05 has no GEM, also at certain times no rhyme or reason, the cluster goes blank, radio goes blank, and door functions quit then again and no certain time you here a relay click under the dash and everything comes back to life and yes checked codes with scan tool and is throwing several codes from cluster communication error to 4x4 to tranny slip to t case issues what the heck is going on?!
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Old 11-12-2013, 07:30 PM
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So here is what I have come to conclude thus far.. Since no advice is here yet I found the relays by the driver side battery, both smoked wet and corroded. Replaced them and the transfer case was clocking as I was trying to get the relays in. Got them in and started the truck still in two wheel drive it locked itself in 4x4 low and wouldn't come out, sounded weird goin in to 4x4 low as well. Removed the transfer case motor assembly and it smelled terrible, checked my motor and it got smoked no continuity through the motor and tried turning the gears by hand and it was TIGHT!! So went one step further and found the 4x4 module which does exist contrary to popular belief, it's behind the glove box in the upper right corner, so I will have my new motor tomoro and if it still doesn't work right will be getting a new 4x4 module, so my question now is would the relays getting wet mess up the 4x4 module to be continuously putting voltage to the transfer case motor causing it to burn out? Or is there something else that I'm not finding?!
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