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Discussion Starter #1
My 4x4 wouldn’t engage one day, took it to the dealer under what I thought would be warranty work. However I was 50 miles past my warranty and they would not cover it. $700 for new motor(no longer doing business with them) so I paid $100 to get my truck back and the diagnosis. Bad 4x4 motor, so buy a new motor hook it up to test and the motor doesn’t move when I move the shift knob from 2 to 4H or 4L. I’ve checked all the fuses under the hood related to the 4x4. Anyone know of any other issues I could be overlooking?
 

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Discussion Starter #2
Also I checked and it is getting power to the motor side (2 wire) I don’t know what should have power on the secondary plug. Every time I go to switch it to 4x4 it just says check 4x4 no code is generated for my scan tool to check.
 

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I'd mount the new motor to the t-case. It could be needing to make a ground thru the housing to operate properly.
 

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Discussion Starter #4 (Edited)
I'd mount the new motor to the t-case. It could be needing to make a ground thru the housing to operate properly.
Tried that was well, no change. If anyone can confirm it grounds in this way I'll get under it again with a wire brush and clean it all up.
 

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Discussion Starter #5
Tried manually locking the hubs and that gave no change. Any ford techs or people see anything like this before?
 

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To add to what @powerstrokeshellback posted ...what are the codes? a generic scan tool(you didn't say) wont get all the codes for these trucks -- something like Forscan will tho
 

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Discussion Starter #8
The display shows it’s switching or trying to at least from 2x4 to 4x4. I would have imagined when it was at my dealer they would have told me the correct issue. I’ll pull the dash and find out. I’m using a SCT4 to check codes.
 

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With the shift motor removed can you turn the shift rail and put the transfer case in the different gears?

Park brake on -- Trans in neutral -- rotate the drive shaft by hand -- may need to jack the rear up to rotate that shaft

The encoder on the shift motor tells the dash what gear is selected
 

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Discussion Starter #10
With the shift motor removed can you turn the shift rail and put the transfer case in the different gears?

Park brake on -- Trans in neutral -- rotate the drive shaft by hand -- may need to jack the rear up to rotate that shaft

The encoder on the shift motor tells the dash what gear is selected
I tried to move it by hand, I didn’t want to put much force on it but it didn’t easily move in either direction.

I’ll try jacking it up and moving the drive shaft to see if that does anything different.
 

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Yeah jacking the rear up is the best option -- need the tension off the driveline to ease the shifter -- if you cant move the shifter shaft, then chances are the shift motor cant either

Trans in neutral -- both front and rear driveshaft should be able to rotate by hand -- then try shifting the transfer case -- you should be able to hit all the positions
 

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Discussion Starter #12
Yeah jacking the rear up is the best option -- need the tension off the driveline to ease the shifter -- if you cant move the shifter shaft, then chances are the shift motor cant either

Trans in neutral -- both front and rear driveshaft should be able to rotate by hand -- then try shifting the transfer case -- you should be able to hit all the positions
With the motor out it moved fine on a battery.

Jacked the truck up and could turn the transfer case by hand. Truck recognized it being in 4 low with the hubs in auto (no vacuum leaks) I reattached the motor and I had left it set for 4 low. It recognized 4 low still but gave me the check 4x4 light again but while turning off traction control and illuminated 4 low.

I took a battery to the motor installed to the case and it turned it from 4 low to 2x4.

Maybe a part of the switch has gone bad?
 

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Have you checked the switch yet?
Not sure in this year of truck, but in the older models -- the switch was just an input for the 4 wheel drive module -- and a relay ran the motor
 
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Not sure in this year of truck, but in the older models -- the switch was just an input for the 4 wheel drive module -- and a relay ran the motor
Yeah, I think your right but the module still needs the input from the switch. Is probably around 4.5-5 volts DC.
 
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Discussion Starter #16
Have you checked the switch yet?
Not sure in this year of truck, but in the older models -- the switch was just an input for the 4 wheel drive module -- and a relay ran the motor
I’ve tried searching but can find zero info on the switch or anyone else having a similar problem. I would think it works as it can tell it’s going out of 2x4 into 4x4 but it just shows a check 4x4 instead of displaying 4high or low. I can get a used switch on eBay for $30 so I might give that a shot.
 

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ok...
i had the same problem replaced th motor, ceck
replaced the switch, check
re0laced the 4x4 control module behind the glove box, check
finally after taking it aart about 5 times and cleaning the connections under the truck several times it just started working :look:
pretty sure it was a connection for me, lots of scraping and electrical cleaner but after not finding anything tht didnt check out and putting it back together (again) it started working :tard:

but there are also two relays one to engage 4x4 one to disengage. they are about 20 bucks each at orealies or auto zone, wouldnt hurt to check those out too while you are tinkering and good luck.

i hope that helps
 

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Discussion Starter #18
ok...
i had the same problem replaced th motor, ceck
replaced the switch, check
re0laced the 4x4 control module behind the glove box, check
finally after taking it aart about 5 times and cleaning the connections under the truck several times it just started working <img src="http://www.powerstroke.org/forum/images/smilies/look.gif" border="0" alt="" title="look" class="inlineimg" />
pretty sure it was a connection for me, lots of scraping and electrical cleaner but after not finding anything tht didnt check out and putting it back together (again) it started working <img src="http://www.powerstroke.org/forum/images/smilies/tard.gif" border="0" alt="" title="tard" class="inlineimg" />

but there are also two relays one to engage 4x4 one to disengage. they are about 20 bucks each at orealies or auto zone, wouldnt hurt to check those out too while you are tinkering and good luck.

i hope that helps
Are those relays under the hood or on the passenger side box?
 

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under the hood drivers side near the fire wall .
 

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Discussion Starter #20 (Edited)
under the hood drivers side bear the fire wall .
is it these two listed as low to high and high to low?

Just checked my manual and it doesn't list these relays for 4x4 or as I have attached since that image is from an 08.

What year was your truck?
 

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