Transfer case asleep at the switch!!!

[ILUVULU]

I have a ’02, F250 with a strange transfer case problem. Automatic transmission, electric transfer case selector switch on the dash. If anyone has any ideas, I would love to hear from you.

I thought my transmission was toast! My son was plowing the road and got stuck. In his efforts to get out he switched to low range and the truck gave up the ghost! It would not try to move forward or reverse. It acted like it was still in park or neutral. As I was taking the transfer case off, I found that my transfer case is hung in neutral! The actuator was in a mid position.

Once I pulled the actuator from the side of the transfer case and actuated the transfer case by hand. If works fine all the way through, 2 – 4H – N – 4L. With the actuator hanging, I cycle the selector switch. The actuator pretty much stays in the neutral position. It cycles about 5 degrees when switched between 2 and 4H. It does not move at all when switched between 4H and 4L. As I test the actuator on the bench, it moves full stroke, about 60 degrees. I assumed it was the position sensor that was faulty, so I picked up a new actuator from Ford this afternoon and the new one behaves exactly like the old one. Therefore it isn’t the actuator but something that drives it.

I checked the engine for DTC’s – None. I pulled the battery cables in case there was some other transmission codes that might be reset by that stunt.



Any ideas? Thanks for your time.

It is one of the rarest things on these trucks to have the 4x4 switch actually go out. But if you are certain thats it. I have a brand new one in the box that a customer had me put it cuz he thought that was the prob. When it didnt fix it he told me to take it out then through it at me. I will send it to you for cheap if you want it.

[ILUVULU]

Thanks for the offer! But, I have figured out the position sensor is fine as the new one behaved exactly like the old one. Something else is at work here...I just don't know what.

but make sure you check EVERYTHING structurally! I have seen these things grenade on plow trucks!

[ILUVULU]

Thanks for the input! Everything looks good from the drive train standpoint. With the drive lines off, I can roll the rear output shaft by hand and feel the action off the drive parts. As I manually move the actuator shaft from 2 to 4H to N to 4L everything feels as I expect it should. Smooth and solid.

I hope its not the motor. They are about $700!

[ILUVULU]

No the motor part of the actuator is good. It bench tests fine.

I think it must be in the wiring somewhere or in the processor that controls it.

Is there any safety system lock that drives the transfer case to a neutral position? My son was not particularly careful when he put it in 4L. He did not wait in neutral for the 4L light. Is there some magical reset somewhere?

Not that I'm aware of.

[ILUVULU]

Bummer...I like magical resets!!! LOL