New transfer case motor installed- reprogram necessary? - Ford Powerstroke Diesel Forum
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Old 11-29-2009, 09:59 PM Fanatic

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New transfer case motor installed- reprogram necessary?

Hey guys- I've been reading threads on here and the diesel stop for literally 4 or 5 hours regarding this issue.

OK- I put in a new transfer case motor earlier today, as the old one had broken gears.

Started truck. Select 4 hi, works fine. Select 4 low, works fine.

Now, when I went back to 4 hi (yes, I did follow instructions in the manual) the dash lights dimmed for a second as if the motor was turning, then nothing. The fuse for the transfer case motor blew, case still in 4 low. Replaced fuse, tried again, blew fuse again.

I removed the motor, put the transfer case in 2 hi manually. Replaced motor fuse, then turned key to run and selected 2 hi. The motor turned back to that spot just fine when not connected to the transfer case.

What is the deal? Obviously, the relays are good as the motor will move both ways- it just wont take the transfer case OUT of 4 low. When I manually shifted it, it wasn't very difficult, and I was using a pretty short adjustable wrench with not much leverage.

I THINK I read somewhere about a module needing to be recalibrated, reprogrammed, or something. Anyone know about this? I can't seem to find anything about it again.

Everything else works fine as far as hubs and all.

Thanks for any help. Sorry this was so long.
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Old 11-30-2009, 11:40 PM
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Hmmm, that sounds like a shift fork or rail problem or a bad replacement motor. Is it harder to turn it back to 2H from 4L than turning it the other way? I’ve replaced a motor and rebuilt two others and or had any trouble. There is nothing to reprogram that I know of, all the motors I have worked on had simple contacts inside that tell it how far to move not a computer.
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