Ok, I have 1996 ranger 4.0, 4x4, 5 speed. I don't know if this has anything to do with the problem, but it's what was going on when all this happened, so I'm throwing it in. I was driving on the interstate messing around with my ac, turning the **** from hot to cool, because the blend door hangs up from time to time and I can sometimes get it to unstick. Well I could hear it clicking as usual, but this time I hit the dash right around the glove compartment with the palm of my hand. Then I pressed the gas pedal and the truck felt like it was neutral. It was still running, but no matter what gear I put it in it wouldn't grab, just felt like neutral. I came to a stop beside the road, and turned it off. I started it back and still nothing. I decided to try 4 wheel drive. Mine has the automatic transfer case, so I turned the **** on the radio bezel to 4 wheel. It then would pull out and would drive fine shifting through all the gears with no problem. So I went to take it out of four wheel, and I heard the usual clicking from the transfer case when it shifts, but it still drove like it was 4 wheel low. No matter how far I backed up and did all the usual tricks to get it out of four wheel, it still drove like it was in low. I got a tow truck ride home and messed around with it in the driveway and it still drives like it's in four wheel low. I jacked the rear wheels off the ground and they are the only ones moving. I left the front hubs unlocked and had a buddy watch the front driveshaft start turning when I turned the 4 wheel drive **** on, and then stop turning when I turn it back to 2wheel. I then checked the ATF level in the transfer case and it was completely empty. I filled it up and the truck is still doing this. Sorry this is so long, I didn't want to leave anything out, because this is my daily driver, and I could really use some help. I'll answer and all questions anybody has.

 

Welcome to the forum

The 1996 Rangers used a Relay box in the dash, Electric shift control module, it basically has 2 relays inside that the GEM module, in the dash as well, activates to power up the shift motor on the transfer case.
By "tapping on the dash lightly", lol, you may have activated a relay or GEM and caused power to be sent to shift motor putting transfer case in Neutral.
But thats unknowable

If you go here: How to: Rebuild 4X4 Shift Motor | Ford Explorer and Ford Ranger Forums - Serious Explorations

There are pictures of the transfer case with shift motor removed, just 4 bolts.
You can see the shift rod and it is pointing at 2WD(2H), you can manually rotate this rod to 4H and 4L, it doesn't rotate 360deg, just from 2WD counter-clockwise to 4L then back to 2WD
Neutral is opposite 2WD and not indicated but it is there, between 4H and 4L

Make SURE you block the tires
Tie up shift motor out of the way
Manually select 2WD and see if it is indeed in 2WD, if not then internal damage of transfer case has occurred from no fluid

 

I forgot to mention that I did remove the shift motor and it was in the 2H position. I manually turned the rod with a pair of vise grips to make sure. The transfer case is off the truck now and when i turn it by hand I can hear grinding and something jingeling around. I've ordered a new one.

 

Good call :)

 

Where exactly is that electric shift control module located at in the dash and what does it look like?

 

The GEM controls the 4WD system in a 1996 but there is a separate Shift Module that has 2 relays inside, not very big.
It is usually located under Radio, behind climate control system
It is black plastic about 2"X3" and has 7 wires

These rarely fail, usual problem is either fuses, the shift motor or the GEM, in that order

 

Well like I said before I bought a transfer case and replaced it. The truck ran fine for about three weeks. After that I was on the interstate driving and the truck slowed down suddenly for a second and I heard a grinding noise then it went away. After that I kept hearing a clicking noise coming from the dash somewhere. I continued to drive and when I finally stopped for the first time and started to pull out it was making a grinding and clunking noise. Like the whole transfer case or transmission was falling out from under it. I stopped again and pulled out and it was fine. I'm assuming the truck was trying to go into 4 wheel while I was driving and finally was able to when I stopped. I removed the shift motor and I'm still in two wheel, but it just doesn't drive the same now. I hear a whineing noise as I accelerate and it feels kind of like it did when my last transfer case went out. I removed the fuse for now so it doesn't try to switch into 4 wheel again. My transfer case is under warranty so I'm picking up a different one Friday.

 

Yes, if shift rod was pointed at 2WD and you were hearing noises and/or feeling a drag then transfer case would be the issue

Could have been issue with GEM trying to shift transfer case but it is "shift on the fly" so while not optimal for it to shift when it wants to, lol, it wouldn't cause any damage to transfer case by shifting to 4WD while driving
It couldn't shift to 4LOW because that requires 0 MPG on speedometer, Transmission in Park/Neutral(or clutch pedal down to floor, and Brake lights must be on(foot on the brake pedal).
Now if GEM was failing I suppose it could try and shift to 4low, but I don't think the electric clutch would let it will moving

 

hmmmm. Maybe the sudden stall and the grinding and clunking is just from the transfer case that I bought being bad. We'll see Friday when I replace it. I'll keep you updated

 

[QUOTE=RonD;2121120]Yes, if shift rod was pointed at 2WD and you were hearing noises and/or feeling a drag then transfer case would be the issue

Could have been issue with GEM trying to shift transfer case but it is "shift on the fly" so while not optimal for it to shift when it wants to, lol, it wouldn't cause any damage to transfer case by shifting to 4WD while driving
It couldn't shift to 4LOW because that requires 0 MPG on speedometer, Transmission in Park/Neutral(or clutch pedal down to floor, and Brake lights must be on(foot on the brake pedal).
Now if GEM was failing I suppose it could try and shift to 4low, but I don't think the electric clutch would let it will moving

Well I replaced the transfer case with another one. When I took the old one off last night the output shaft seal was shot, and the bearings behind them where in pieces and it was leaking fluid. That explains all the noises I heard that day. Any ideas why this would have happened? I cleaned the housing on the transmission where the transfer case attached. It was caked with what looked like brake dust. I sprayed it out with brake cleaner and wiped it out.