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new transfer case shift motor doesnt line up

  #1  
Old 12-13-2018
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new transfer case shift motor doesnt line up

99 4.0 automatic has the 4x4 blinking light but refuses to engage into 4wd. Figured Id start by replacing the shift motor after reading that is a common cause. Picked up a rebuilt trasfer case shift motor but there is a slight difference where 2wd is marked on the old unit vs the rebuilt unit. The new unit is about 5 degrees off. I tried putting the motor in neutral and moving it but it will only allow me to move it towards 4x4
Is there a trick to this?
 
  #2  
Old 12-14-2018
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Welcome to the forum

Remove new shift motor
Hook shift motor up to wiring harness
Select 4hi and then 4low
Make sure it is moving and lights on dash work
Then select 2WD

See if it lines up now, if not then you can adjust the cover over the contact wheel, which moves the contacts

Pictures here of shift motor disassembled: https://www.explorerforum.com/forums...-motor.123542/

The contact wheel "tells" the controller where the shift motor is, tells it when to stop moving when its in correct position
Loosen screws and move cover plate a bit, re-tighten screws, then plug it back in and retest, shifting to 4hi and then back to 2WD
 
  #3  
Old 12-14-2018
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Thanks-
I hooked up the new one---I dont see anything moving.
I had the truck in neutral, and tried in park, nothing moving. Next steps?
 
  #4  
Old 12-14-2018
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In 1999 Ranger 4x4 system used the GEM module to control 4WD shifting, AND a Relay module to power the shift motor
Check Fuse #3 in engine fuse box, that powers the shift motor, 20amp fuse

When you select 4WD or 2WD you should here a "Click" from behind radio, thats the GEM activating the shift relay
If no "click" then either relays have failed or GEM module has
You need to remove the radio to access both of these
GEM is on the left and Relay box is between GEM and firewall so next to GEM on the left

GEM runs all the cab electrics, and there is no way I know of to test it
Relay module is just two 12v relays in a box so you could test it with ohm meter and 9v battery
 
  #5  
Old 12-22-2018
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Just pulled everything apart. Got the new motor lined up, and installed. Still getting the blinking lights. I do hear multiple clicks behind the radio when selecting 4 hi, however nothing happens.

any ideas?
hubs next?
 
  #6  
Old 12-22-2018
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Fuse #3 in engine fuse box?
This only powers the shift motor, rest of the system get power elsewhere, so "clicking" sound doesn't mean all fuses are OK

I would have tested motor first before installing, it will work if you just have the wires plugged in, doesn't need to be installed to move/change positions

The flashing means shift motor is not moving when activated, which you know already

Automatic hubs are slaves to the system so can't effect the shifting in and out of 4WD, if you are IN 4WD and front wheels are not Pulling then it can be a hub problem
 
  #7  
Old 12-22-2018
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So, I pulled fuse #3 out of the engine fuse box last week, looked it over and it looked fine. Wasn't blown, looks new, no issues....
Just for giggles, I just ran down to a local hardware store and grabbed a 20 amp fuse, and replaced #3 and it went right into 4wd...

I thank you RonD-

Anyone searching this thread....try fuse #3 first if your having the blinking 4wd hi / 4 lo lights.
The fuse was 39 cents
The shift motor was $169 + 30 for the core.
 
  #8  
Old 12-22-2018
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Good work

Eye balling is great for watching the ladies, but has about the same reliability as eye balling a fuse when trying to tell if either is a good one or has a broken wire inside :)
I've had my share of broken wires in BOTH, but one is more fun to test than the other
 
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