ESOF has me stumped

[Nolooseends]

I know there's ESOF questions on here all the time but I've read through about every thread the search brings up and havent figured this out:

About 2 months ago the electric actuator went out on my ESOF transfer case so I replaced it with a new one I found on Amazon.

New motor worked fine through several test shifts in my driveway and even once when I got stuck and needed it. Hard to believe right?

Then when I tried to shift out of 4x4 it wouldn't so I unlocked the hubs (still unable to turn the front drive shaft by hand since transfer case was still engaged) and drove on it for about an hour until randomly the 4x4 light in the dash went off and I was able to turn the front driveshaft.

When I got home I turned the key on and cycled through the 4x4 switch in park, neutral, and with foot on and off the brake and was unable to get the electric motor to engage or to hear the relays click.

I have checked the 5 relays under the hood, all of the relays under the dash, and the 2 fuses related to 4x4 in my owners manual to no avail.

I don't think the motor could have gone bad again already but as far as I know that's all thats left. Whats the best way to test power to the electric motor?

Thanks in advance

[BigD214]

What year is your truck?


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[Nolooseends]

It's a 2003

[BigD214]

There is a possibility the your GEM (general electric module) is going bad. The GEM controls all your non power train systems. So if your GEM is fuzzing out on ya then it could cause your transfer case motor to act up. Also does your windows and radio turn on and off randomly


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[Nolooseends]

That makes sense. My radio quit coming on with the key a couple months ago and I ended up putting it on a switch. The windows still work though.

[BigD214]

Yea it sounds like to me your GEM is going out on ya... I am have the same problems with my truck. The only way to fix your GEM is either to bypass it or replace it but replacing it would entail replacing your whole instrument cluster.


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[Sticker Monster]

Originally Posted by BigD214

Yea it sounds like to me your GEM is going out on ya... I am have the same problems with my truck. The only way to fix your GEM is either to bypass it or replace it but replacing it would entail replacing your whole instrument cluster.


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why would you have to replace the instrument cluster? here is the factory service procedure for replacing the gem. note this info is from the 2000 workshop manual, but is likely the same as for your 2003.

SM

[BigD214]

Originally Posted by Sticker Monster

why would you have to replace the instrument cluster? here is the factory service procedure for replacing the gem. note this info is from the 2000 workshop manual, but is likely the same as for your 2003.

SM

Stick monster so if I understand this correctly all I would have to do is get the GEM reflashed and it would fix my problems? And that's what iv read on how to fix the GEM


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[ZMANN]

Hang on fixing link

EDIT darn site is having a prob loading EDIt site up again

it gives you a good understanding of what GEM's need programmed and what ones do not

also why they fail ,, ford has an issue with water intrusion

http://blog.autopartscheaper.com/?p=38

[Sticker Monster]

Originally Posted by BigD214

Stick monster so if I understand this correctly all I would have to do is get the GEM reflashed and it would fix my problems? And that's what iv read on how to fix the GEM


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I don't know about reflashing YOUR gem, not sure that's possible since it is usually a hardware failure inside the gem.

SM