Hello all,

I have a 2002 Ranger, 4.0 V6, automatic transmission and am having a stubborn 4X4 issue. I've read through the forums here for directions and have tried everything I could think of based on what I've read on these forums and around the internet.

Problem: When I turn my 4X4 switch, I get nothing. No lights on the dash, no "click" sound from the 4X4 control module in the passenger side kick panel, nothing.

Attempted so far:

1. I've checked all of the fuses in both the cab and the engine compartment, and did not find any blown fuses.
2. I swapped out the 4X4 control module and that did not fix it (though the lights on the dash flash when I start the truck so I have read that means the module is good as well).
3. I have a new Dorman transfer case shift motor on there now, that did not fix the issue.
4. I've also tried replacing the 4X4 selector switch in the cab, and that did not fix the issue either.
5. I verified I have connectivity from the selector switch in the dash to the appropriate pins in the connector going into the 4X4 control module (thought maybe a broken wire or mouse had chewed, etc.).

This has to be something electrical, but I am out of ideas. I am hoping someone may have a direction you could point me in to check next? I'm headed to the parts store at some point to see if they can scan for any codes.

Matt

 

Some if not all of the wiring for 4x4 passes through the floor underneath the driver's seat. There's a large connector there, and they are prone to moisture getting into the connector, which causes corrosion. You can try to get to the connector from underneath the truck, but you can also get to it if you remove the driver's seat and lift the carpet. Undo the connector and check the pins for any corrosion.

 

Make sure the new ControlModule has the same 1111~2222~33 1st~2nd section of the part#s as your original;
3rd section of part# can be the same or later build; several differing 1st~2nd# versions over the years are NOT compatible.
Check all of the connection pins & wires on the ControlModule & ShiftMotor for bent pins or damaged wires.
Pull the ShiftMotor off the TransferCase stem; have someone in the cab operate the 4x4 switch in Neutral with foot on Brake.
Watch the motor; confirm it cycles 2WHi~4WHi~4WLo & back; if it does the TransferCase itself may have an issue.

 

Thank you both for the suggestions. I've checked the large connector that Fordzilla80 mentioned underneath the cab and the pins there look fine, all looked very clean (seemed to have been sealed up pretty well).

I would imagine that if the transfer case had an issue or one of the wires going to the shift motor was bad I would still hear the click of the 4X4CM when I turned the switch right? I will check the pins going to the 4X4CM tomorrow, that's a good idea.

Some posts here indicate that on the '02 the 4WD HI and 4WD LOW lights on the dash illuminating briefly when starting the truck indicate that the 4X4CM is good, is that always the case? Or is there a situation wherein the module might send power to the lights on the dash during the startup sequence but the module might still be wonky? I will check the part number on the new module I purchased from AutoZone, did not think the part number made a difference so thank you for that information.

 

As a PSA to others who may be experiencing the same symptoms described in my post, this has been fixed. It turned out to be a broken wire underneath the truck, between the large connector in the floor and the transfer case motor. The broken wire was the yellow/white wire (labeled MOTOR 1 I believe on the wiring diagram I was working off of). Thanks everyone for the suggestions!

 

Good work finding that

Thanks for the followup post
That was an unusual problem, not all a common failure point in Ranger 4x4 systems