I bought a 99 for my son and the xfer case motor would not work. After a reset on fuse 25 I got some motion from old motor but then it failed again and got blinking dash lights. I bought a new motor but it’s the 600-807 doorman motor and it throws the light codes. The guy at the store said it’s the right part but not sure now as it lists 2000 to 2005 Ranger applications x and I think ford switched to a separate control module around then. With the new motor plugged in but disconnected from the case I can get 4hi and the system is happy. If I switch to 2hi the motor moves but then I hear clicks repeatedly until the system shuts down and blinks the lights. Same if I go to 4lo shifts but seems not to get the right signal.
since the relay and GEM seem to be doing their job I am 90% sure they are ok and the motor is incorrect or maybe the GEM contact for the 4lo/2hi from the motor is wrong But not sure. (Saw a YouTube vide where a guy breaks down what wires make contact when). Could also be that the motor in 2001 plus models is different??

I have been looking at this system for a couple of days so if I am wrong here on my thinking let me know.

Looking for help on next steps:

Does anyone have a pin/connection diagram of what is grounded when on the transfer motor sensors? For both the 1999 and the later 2005? I could compare and rule out the new motor.

I can plug in old motor but the brown wire needs to be moved and it’s a pain. But might be a good test of GEM and seeing if a wire to gem is broken. If not broken then might point to a GEM issue

Get a 1999 Cardone motor from Orileys. Swap in and see if that work. But could rule out with knowing pin outs for 1999 vs 2005? motor.


Help please. Spent last two days under truck in 35F weather. 🥶. Need to get 4x4 going as we got snow weather.

thank you.

 

Ok an update. I went to put in the new motor back on so I can store the car on the street. The motor would NOT go in. Last test case with the motor disconnected was to put it in 2hi. I put the selection switch to 2hi and the motor moved to 2hi until it threw a code. The motor basically over rotated until it hit a hard stop inside the motor case.
To get it back on I reset the system and put the motor in 4hi while disconnected. This position works with my system. Then I moved the transfer case to 4hi and reconnected the motor to the case. I left it there for now.

So I think the system is not sensing one of the connections on the motor. Still not sure if the 2005 motor I have has a different position or if the GEM or a wire to the GEM is broken. Everything else is working but the system can’t register 2hi or 4lo. 4hi is fine.

Any thoughts?

 

The Brown wire was only used up thru 2000 its for an electric clutch inside transfer case, you can just splice the two brown wires together and leave them out of the 8 pin connector, if you want

As far as I know Ford never changed the wiring on the 8 pin connector, 1983 thru 2011, on the vehicle side
The shift motor side wire color can be different by manufacturer, its what NCA mean in below diagrams, No Color Assigned

Here is pin numbering for 8 pins: https://lh6.googleusercontent.com/-0.../transcase.png

Below are 1998 and 2006 4x4 wiring diagrams, same pin numbers for both years, engine size or transmission type didn't matter

The solid Yellow and Orange wires power the motor, BOTH should shows as Grounds with key on, only 1 wire is changed to 12v when motor is activated, which wire decides the direction the motor will spin, same as Power Window motors work

Other 5 wires are for the 4 contacts inside the shift motor housing
As seen in the diagrams Yellow/white wire is the baseline wire
The other 4 wires are either connected to it or not connected to it based on the position of the shift motor's transfer case connection

The shift motor doesn't need to be grounded to transfer case to work, if removed and plugged in it should move to correct position using the dash switch
If its not then the new shift motors 8 pin connector may have been mis-wired when made, these ARE NEVER TESTED
If possible return it for another one

 

Ron! I was thinking the same thing. Based on the truth table you posted for someone else if two of the pins are swapped this could occur. First step is to take old motor and see if i can get it to send right signals. Then I can comp to the new motor. But if old motor works I might return the new one.

I think I will cut the brown wire and reroute as you suggested. Pulling that wire out with my eyesight takes forever.

 

@RonD the truth table for the sensor you posted elsewhere seems off. It references pins 4-8 for the switches. But the schematics show 1,2,3,5,6.
is there a truth table for the Ranger?

 

Ok. Never mind. I realized the truth table colors match so just need to renumber the pins.

 

For future searchers.

Update on situation. The 1999 motor is apparently different from 200x to 2005. The 1999 specific motor works and 4x4 is working now. The part I ordered was from NAPA. It ends in 202. I think this is the 202 Cardone motor repackaged.

I also found that doorman thinks their 1999 motor does not work, and is only applicable to the EV version that year. Of course EV was 2x4 only and had no transfer case so doorman is wrong.