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So I have a 2003 F350 6.0 and when you shift it into 4wd hi or low nothing happens. No lights on the dash come on and I have tested and there is no power going to the motor on the t-case. Any ideas? I have tested all the fuses I could find and have switched out relays under the hood to check that, but still nada. PLEASE HELP the snow is about to fly
 

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I am having the same problem. i've been searching post but not finding this same situation. Mostly hub problems.
 

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Did you find the problem yet?
 

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I replaced the motor on the transfer case but still nothing. I can hear the relays clicking under the hood when I turn the switch but its not engageing. No light on the dash or the switch. Also no sign of vacume leak. a/c stays the same when I turn 4wd on.
 

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So, there is now power at the TC switch motor? My next question is did you manually turn the engagement shaft when you had the motor off to see if it would engage easily, before putting the new one on? I can't remember the exact motor logic anymore, but it tries for about 20 seconds to engage before it cycles itself off. Unfortunately, the ESOF can be a PITA when things stiffen up in the TC. It is always a good idea to cycle it and run it in 4x4 on a regular basis, just not on a hard surface.

The light comes on when the motor has rotated the shaft to the correct position.
 

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I did not try to turn the shaft. I take it that it will get bound up internally if not used often. I bought the truck 8 yrs old with 20,000 miles on . its got 27,000 now. I was hoping it would'nt be anything internal with that low milage. Will moving it manualy get it to loosen up or do i have to move it then drive it and then move it back? Also only one pin had power to the motor . I did'nt know if they both should or not. Thanks for help. Im kinda stuck.
 

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Also have the same problem, mine is an 03 also, out of curiosity does your 4x4 switch light up with your parking lights on, mine are out, wondering if we have the same symptoms, maybe we can both figure this out, im very frustrated.
 

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No the switch does not light up at all. The 4X4 and LOW RANGE in the instrument cluster only light up when I start the engine and then go out like all the others. Nothing lights up when I turn the 4x4 switch.
 

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No the switch does not light up at all. The 4X4 and LOW RANGE in the instrument cluster only light up when I start the engine and then go out like all the others. Nothing lights up when I turn the 4x4 switch.

We have the same exact problem, all my fuses and relays check good, i pulled the motor off the tcase and the 2 wire plug for motor operation has no power going to it, i have power at the switch.

Ive been told there is a separate 4x4 moudle behind the glovebox, but ive searched and everything comes back to the gem module.

My 4x4 also lights up when you start the truck but them goes out.
 

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the 4x4 and dash light are tied to the PCM

the system has no clue what so ever if the hubs did anything

but the transfer case motor has some hall effect sensors and can tell if the motor moved to the expected position and then will turn the dash light on accordingly
 

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I do have power to one of the two pins at the motor when the switch is turned but its only one. I was afraid that it is the GEM also. I just read about that. Someone said you can by pass it but there were no details as to how. Twoicebergs asked about turning the shaft. I will be trying that in the morning. This is my first truck with this electronic crap 4x4. So far it seems better for the parts suppliers than the truck owner. IMHO
 

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I do have power to one of the two pins at the motor when the switch is turned but its only one. I was afraid that it is the GEM also. I just read about that. Someone said you can by pass it but there were no details as to how. Twoicebergs asked about turning the shaft. I will be trying that in the morning. This is my first truck with this electronic crap 4x4. So far it seems better for the parts suppliers than the truck owner. IMHO
I can turn mine with a 16mm wrench in all positions but you have to figure out what position is what, i clicked mine into 4HI for this storm we just had but obviously having to do this sucks. I cant find any evidence there is a separate 4x4 module other than the GEM for our model year, can anyone verify this?
 

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No. Sorry. I just heard about it myself searching the forum. How hard should it be to turn the shaft with a wrench and which direction does it turn? clockwise or counter clockwise? The GEM is said to be behind the glove box.
 

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What is a GEM? Not hijacking but my Dads 03 is doing the exact same thing, turn switch and no lights or engagement. Subscribed.........
 

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No. Sorry. I just heard about it myself searching the forum. How hard should it be to turn the shaft with a wrench and which direction does it turn? clockwise or counter clockwise? The GEM is said to be behind the glove box.

I think from the 2wd position you can turn it clockwise or counter, could be wrong it should turn easily. Also i am usure if there is a neutral position.
 

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I guess its a controler of some sort for the 4x4 system. I guess the old tried and true method of grabbing a lever to enguage the 4 whell drive was too simple.
 

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I guess its a controler of some sort for the 4x4 system. I guess the old tried and true method of grabbing a lever to enguage the 4 whell drive was too simple.

I agree wish i had the sure stick in my truck. Of course mine fails in the biggest snow storm we have had in years. Im leaning towards my GEM module but its kinda pricey to just throw one at it. Anyways these can be tested with a scantool or something? Any ford techs that would know? I think you can pull codes from this module.
 

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I would love to figure this out all the threads i have read on here seem to lead to dead ends. I did see one where a guy had a broken wire underneath the relays under the hood, i am going to inspect this area on my truck and go from there
 

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u can pull codes with a good reader

the GEM doesn't just usually fail one item and I am not sure the 4X4 runs through the gem anyway ? I do know it is a PCM /ECM 's job to send the signals out to the TC shift motor and ESOF solenoid


the chances are greater the Transfer case motor or wiring have failed

specially if u hear relays clicking ,, but it could be the relay as well


I have all the manuals but have not had to dig into this system yet
 

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Yeah. I couldn't find anything that really helped with this problem very much. Might not have used the right search words.
I do understand how to troubleshoot the vacume hubs. Another brilliant idea. Lol
 
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