Hi Guys,

Working on my dad's 2011 4.0 Electric transfer case.

Here goes. If you put it in low range it will not come out. Changed the motor on the transfer case. New one does same thing. Hot wired them to check each of them. They will go full rotation both ways with no issues or noise.
Plug either in to the truck and it will usually go to 4hi maybe return to 2hi then if does it decides its not going to 4hi and when it goes to 4 low it's never coming back.

I can hear what sounds like relays clicking right behind the 4wd ****. But that doesn't mean its going to turn the motor and sometimes it starts to move then stops and starts again.

At this point I'm sure it's electrical or a control unit.

Has anyone had this same issue?

A wiring diagram, if anyone has one would be great. Maybe a trouble shooting chart?

Long story short I got the motor to 2hi and manually shifted the transfer case to 2hi. Pulled the fuse and told him drive it as a twd until I can get some information.

 

Not quite a trouble shooting chart
From my notes:
The 4x4CM (control module) it’s behind the radio.
First check Fuses 10, 22, 27 and 28 in cab fuse box remove and test with an ohm meter if necessary.
These all power the 4WD module.

The dash switch is just 3 resistors, one for each position, 2WD, 4H and 4L
With key on the 4x4CM sends the switch 5volts, it gets back 4v, 3v, or 2v depending on switch position
If 4x4CM gets back 0volts then it will Flash the 4WD lights. Bad 4x4CM= no 4WD lights

The position disc gets dirty too. There are instructions online here for cleaning it.

 

Sorry for taking so long to get back to this. Work has me on the run and now I'm going out of town for two weeks.

The truck is still on the move and it's summer anyway.

Thank you for your response and I will do some good trouble shooting when I get back home. I will let you know what I find.

 

Oh one other thing. lots of the things I read said the CM was behind the passenger kick panel. What year did they change to location for my own reference?

 

From my notes (meaning: NO GUARANTEE of ACCURACY)

The 4x4CM is behind passenger kick panel in 2001 to 2003 Rangers, it was moved to behind the radio in 2004 because GEM was removed from there and to make room for the SJB (Smart Junction Box) behind passenger kick panel.
Also.
Flashing 4WD lights means 4x4CM is working but something ELSE isn't
No flashing 4WD lights means 4x4CM is not working or powered off (fuses)
4x4CMs were an issue on 2001-2011 Rangers