4x4 fuse blowing - Ford Powerstroke Diesel Forum
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post #1 of 16 Old 09-09-2013, 01:32 PM Thread Starter
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4x4 fuse blowing

Hello all,

I have been having some issues with my 4x4 lately. The light would come on the dash randomly going down the road. Then finally quit coming on. I found the #111 fuse blown in the fuse box. Blew the new one as soon as i inserted it into its spot. Thought maybe relays so bought 2 new relays and put them in. The front one made funky shorting noises as i inserted it into its spot. I checked all the wires i could find relating the the 4x4 with no shorts or grounding showing up.

Truck is in sig...

Any help would be greatly appreciated.

Thanks,

Jmiller

2013 F350 6.7 CCLB KR 4X4. No Limit Intake. 4" delete pipe. No Limit Blockoff Plates. SCT Livewire TS. Leveled. 35" shoes.

FOR SALE 2002 F250 7.3 psd crewcab short bed. 4x4. DIY 6637. 4" turbo back mbrp exhaust. PHP Hydra. AIH Delete. Riff Raff CCV Mod. New icp. New cps. New ebps. Rebuilt ipr. 207,000 miles. 4" rough country lift. 05' front end. Driven diesel pre pump kit. Shimmed fpr. Boost guage. Fuel pressure guage. Tranny temp guage. EGT guage. FOR SALE
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post #2 of 16 Old 09-09-2013, 02:04 PM Thread Starter
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4x4 and low range lights on dash still light up right after starting the truck.

No Codes.

No other electrical issues that I know of.

Thanks,

Jmiller

2013 F350 6.7 CCLB KR 4X4. No Limit Intake. 4" delete pipe. No Limit Blockoff Plates. SCT Livewire TS. Leveled. 35" shoes.

FOR SALE 2002 F250 7.3 psd crewcab short bed. 4x4. DIY 6637. 4" turbo back mbrp exhaust. PHP Hydra. AIH Delete. Riff Raff CCV Mod. New icp. New cps. New ebps. Rebuilt ipr. 207,000 miles. 4" rough country lift. 05' front end. Driven diesel pre pump kit. Shimmed fpr. Boost guage. Fuel pressure guage. Tranny temp guage. EGT guage. FOR SALE

Last edited by Jmiller02; 09-09-2013 at 02:12 PM.
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post #3 of 16 Old 09-09-2013, 08:02 PM
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Is it in 4x4? Is anything happening other than random dash lights? Like, shifting into 4low and making you play with the switch to get back into 2wd?

How did you check the wires? Visual or with a meter?

2002 F250 CCSB 4x4
PHP Phoenix, John Woods VB, NUC bypass, 6637

"No country can be called free which is governed by an absolute power;
and it matters not whether it be an absolute royal power or an absolute
legislative power, as the consequences will be the same to the people."

--Thomas Paine, Four Letters on Interesting Subjects, 1776
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post #4 of 16 Old 09-10-2013, 05:58 AM Thread Starter
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It is not stuck in 4x4. Been acting kinda finicky the last month. Needed it 2 days ago and it wouldn't do anything. That's when i found the fuse blown. Still cant get it to do anything because it keeps blowing #111 fuse.

After extensive reading about random 4x4 dash light coming on i was expecting it to be relays but it of course did not work.

No other electrical issues that may point to the GEM.

Maybe its the actual shift motor on the transfer case. Can these short out internally and cause the 111 fuse to keep blowing up?

I checked all the connections to the transfer case motor and all looked good.

Inspected wires visually.

Thanks,

JMiller

2013 F350 6.7 CCLB KR 4X4. No Limit Intake. 4" delete pipe. No Limit Blockoff Plates. SCT Livewire TS. Leveled. 35" shoes.

FOR SALE 2002 F250 7.3 psd crewcab short bed. 4x4. DIY 6637. 4" turbo back mbrp exhaust. PHP Hydra. AIH Delete. Riff Raff CCV Mod. New icp. New cps. New ebps. Rebuilt ipr. 207,000 miles. 4" rough country lift. 05' front end. Driven diesel pre pump kit. Shimmed fpr. Boost guage. Fuel pressure guage. Tranny temp guage. EGT guage. FOR SALE
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post #5 of 16 Old 09-10-2013, 06:14 AM
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Going off of the diagrams, it's gotta be the GEM, assuming all of your wiring is good. Check stuff behind the dash to make sure there's not a short back there.




2002 F250 CCSB 4x4
PHP Phoenix, John Woods VB, NUC bypass, 6637

"No country can be called free which is governed by an absolute power;
and it matters not whether it be an absolute royal power or an absolute
legislative power, as the consequences will be the same to the people."

--Thomas Paine, Four Letters on Interesting Subjects, 1776
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post #6 of 16 Old 09-10-2013, 06:25 AM Thread Starter
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your diagrams are for an f150...same for the f250?

i pulled the dash yesterday and checked everything behind the esof...

2013 F350 6.7 CCLB KR 4X4. No Limit Intake. 4" delete pipe. No Limit Blockoff Plates. SCT Livewire TS. Leveled. 35" shoes.

FOR SALE 2002 F250 7.3 psd crewcab short bed. 4x4. DIY 6637. 4" turbo back mbrp exhaust. PHP Hydra. AIH Delete. Riff Raff CCV Mod. New icp. New cps. New ebps. Rebuilt ipr. 207,000 miles. 4" rough country lift. 05' front end. Driven diesel pre pump kit. Shimmed fpr. Boost guage. Fuel pressure guage. Tranny temp guage. EGT guage. FOR SALE
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post #7 of 16 Old 09-10-2013, 06:33 AM
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I assume so. I honestly didn't see that little note at the bottom. Pulled it off of the Auto Zone repair guide stuff. I don't see a reason for it to be different in an F250.

2002 F250 CCSB 4x4
PHP Phoenix, John Woods VB, NUC bypass, 6637

"No country can be called free which is governed by an absolute power;
and it matters not whether it be an absolute royal power or an absolute
legislative power, as the consequences will be the same to the people."

--Thomas Paine, Four Letters on Interesting Subjects, 1776
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post #8 of 16 Old 09-10-2013, 06:58 AM
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Looked it up in the Service Manual. Same same. However, I also looked up the "Symptom Chart" 4x4 indicator always on gives a few possibilities.

ABS Module
Circuitry
Instrument Cluster
GEM

ABS module test:

Make sure you're in 2wd. Make sure the indicator says 4x4. Disconnect ABS module. See if light goes off.


GEM test:

Shows an image disconnecting "GEM C240c". I don't know if that's the main GEM plug or not, someone else can hopefully chime in. Does the light go off?


Instrument cluster test:

Again, image showing a disconnect of "C250c". I don't know if that's the main cluster plug. Does light go off?

2002 F250 CCSB 4x4
PHP Phoenix, John Woods VB, NUC bypass, 6637

"No country can be called free which is governed by an absolute power;
and it matters not whether it be an absolute royal power or an absolute
legislative power, as the consequences will be the same to the people."

--Thomas Paine, Four Letters on Interesting Subjects, 1776
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post #9 of 16 Old 09-10-2013, 08:25 AM Thread Starter
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Hmmm...the light doesn't stay on. Nothing comes on or works because the esof #111 fuse keeps blowing immediately upon insertion whether the truck on or off or esof switch in any position...

Thanks,

JMiller

2013 F350 6.7 CCLB KR 4X4. No Limit Intake. 4" delete pipe. No Limit Blockoff Plates. SCT Livewire TS. Leveled. 35" shoes.

FOR SALE 2002 F250 7.3 psd crewcab short bed. 4x4. DIY 6637. 4" turbo back mbrp exhaust. PHP Hydra. AIH Delete. Riff Raff CCV Mod. New icp. New cps. New ebps. Rebuilt ipr. 207,000 miles. 4" rough country lift. 05' front end. Driven diesel pre pump kit. Shimmed fpr. Boost guage. Fuel pressure guage. Tranny temp guage. EGT guage. FOR SALE
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post #10 of 16 Old 09-10-2013, 04:47 PM Thread Starter
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Did some more digging underneath the truck...found the upper plug on the transfer case to be loose. Appears the locking ear is broken. So i just unplugged it and let it hang while i tried to insert a fuse into the #111 hole. Used a 40 amp because its all i had left and it once again blew instantly. Could the loose plug have cause my shifter motor on the transfer case to foul up and short internally causing the fuses to keep blowing? I am obviously not very good at reading wiring diagrams to see if this is even possible.

Thanks for all your help so far...

JMiller

2013 F350 6.7 CCLB KR 4X4. No Limit Intake. 4" delete pipe. No Limit Blockoff Plates. SCT Livewire TS. Leveled. 35" shoes.

FOR SALE 2002 F250 7.3 psd crewcab short bed. 4x4. DIY 6637. 4" turbo back mbrp exhaust. PHP Hydra. AIH Delete. Riff Raff CCV Mod. New icp. New cps. New ebps. Rebuilt ipr. 207,000 miles. 4" rough country lift. 05' front end. Driven diesel pre pump kit. Shimmed fpr. Boost guage. Fuel pressure guage. Tranny temp guage. EGT guage. FOR SALE
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