4X4 problem. ALMOST figured out, could use some help please - Ford Powerstroke Diesel Forum
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Old 08-28-2011, 11:00 AM
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Unhappy 4X4 problem. ALMOST figured out, could use some help please

(later 99 f250) So when I bought the truck the t-case motor harness was unplugged and I plugged it back in and had 4wd. It recently went out and now i'm on a wild chase to figure it out. here's what i've done so far.

1.Checked all relays(2 Under hood) even pulled the whole harness out and examined all the wires. seems the relays won't transfer power over to the orange or yellow wires once I turn the fly. thought their might be a short in the wires somewhere so I hooked a live wire up to a fuse and then touched the orange wire and it transferd the motor(so the motor works!) but then started hearing clicking from under the dash, so that takes me to number 2!


2.
pulled the GEM, then put it back in to trial some more stuff.


3. Relays behind the dash! 1 big one and 2 small ones.

the big one has power going to it.
1 of the small one has power going to it(dark green/light green power wire).
then the other relay has the same dark green/light green power wire going to it but no power. hmm?

4. fly switch has power going to it and i took the switch out of the cover it goes onto and put it on as shown in the picture. thought maybe it wasn't making contact to switch it over but it does.

5. then I figured autozone could test the hublock solenoid. I was wrong

.

so i narrowed it down to-
- A loose wire
- The GEM(my wipers,washer fluid, and dome light don't work now
- hublock solenoid.

before you ask i triple checked all fuses. their all good. Any thoughts please?
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Old 08-28-2011, 12:58 PM
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The fly switch is getting power, the solenoid is getting power to it. The relays under the hood are getting power to then but not transferring it, it seems like. like said the only thing that seems out if place is that one dark green/light green wire not getting power to it under the dash. I did hook up a live wire to that green wire and I heard some noise under the truck and when I got under it the gas tank was vibrating when I put my hand on it. Fuel pump? I don't get it.

Only other stuff that it could be is the gem, solenoid, loose wire.
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Old 08-29-2011, 01:51 PM
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no one has any ideas?
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Old 08-29-2011, 02:21 PM
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Lemme see if I can dig up my manual and diagrams.


Sent from my fone.
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Old 08-29-2011, 02:49 PM
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thanks for the reply.

I'm thinking I may have found the fuel pump relay behind the dash? I've read somewhere their is one behind the dash for that also. So I didn't find the 4wd relay behind the dash or did I find a multi-function relay harness? I'm stumped. wishing this didn't happen so I could spend the money on other mods. Winter will be coming up tho
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Old 08-30-2011, 02:17 PM
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Find anything?
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Old 08-31-2011, 03:44 PM
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Sorry. I didn't see anything in the haynes manual for the wiring diagrams. I'll check and see what else I may find that might be helpful.


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Old 09-06-2011, 03:59 PM
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Replaced GEM, didn't fix my 4wd.
Replaced Hub lock solenoid.
didn't fix it either.
had to get my solenoid from FORD for $85 and they have a no return policy on electronics.

hmmmmmmmm
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Old 09-08-2011, 06:37 PM
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Ok, got my one of them pen light looking testers that you ground the end and then touch fuses etc. so I went through everything and everything has power except the blue line going to the 4x4 dash switch but the light blue/white one does but that's ran fir the bulb from the dash lights. I then put the relays back in place for the 4x4 under the hood, then Used the tester and I put it on the brown/white(I think that's the color going to the relay from the gem) and I heard the tcase motor come on. Then I went to the other relay to the wire that goes to it from the gem and the motor came back on.

Bad ground connection? I havnt got a clue. Any opinions?
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Old 09-16-2011, 09:22 PM
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Like you i also lost 4 wheel drive for a while and what i eventually found out after replacing a 280 dollar gem module that a tooth actually sheared off the gear in the transfer case motor assembly and then said tooth made the gear on the motor grind off what ever was keeping it on the motor shaft (i cant remember if it was splined or not or whatever held it to rotate with the motor shaft) so it gave the appearance that the motor assembly was working properly
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