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Old 02-03-2015
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I am: Devin Harper
Join Date: Mar 2013
Location: Meridian, ID
Vehicle: 2004 Ford Ranger
Drive Type: 4x4
Engine: 4.0
Posts: 3
Total Props: 0
4x4 Not Engaging | Shift Motor Repair

I almost got stranded out in the brush because I couldn't get my 4WD to engage in my 2004 Ranger 4.0L V6 man trans. I think it was the 10th try it finally decided to engage. My truck was losing its man card and I wasn't about to let that happen.

The Problem: 4wd not engaging.

Troubleshooting: Do the 4x4 lights in dash flash on and off during engine ignition? Do you hear clicks when you turn the 4x4 dial? If yes to both of these questions, proceed to solution. If not, you have a different problem.

The Solution: Pulled off shift motor off of transfer case by unscrewing 4 10mm bolts and unplugging electrical connection. Took to my work bench and removed the two (thicker) wires going to the motor (black tube about the size of half of a summer sausage). I hooked these wires up to a 12V battery I had laying around and tested the motor. It worked. Upon further research, I found out that the electronic components inside the gray plastic cap where the 5 wires enter were either dirty or oxidized. Problem is, there's no way to get in there and inspect. Unscrewing the three small torx screws won't get you to these wires. The only solution was to drill two small holes in the plastic cap, careful not to damage anything inside, and spray electrical cleaner inside. I let it dry, then mounted it back on transfer case to test and PROBLEM SOLVED. My ranger lives to see another day. I sealed the two holes with some caulk I had laying around. Hope this helps.

Last edited by Devin; 02-03-2015 at 10:11 AM.
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