1999 Ranger XLT Sport V6 4.0, weekend truck, 110,000 miles

Used 4W High last weekend. Couldn't get the truck out of 4X4 even when the electronic switch positioned was at 2W High position.

Pulled transaxle switch motor to see mechanical status and to confirm whether the switch failed. Transaxle switch and transaxle were positioned at 2W. Pulled PVH hubs. When I pulled driver side I heard a sucking sound like I broke the vacuum and the PVH clicked. I'm guessing it was stuck in the engaged position even though the transaxle was set at 2W. Test drove with PVH removed, 4x4 disengaged. It appears the transaxle was in 2W, but the driver site PVH was keeping 4x4 engaged by a stuck PVH. Put the PVH's back in and the truck runs fine in 2W drive. Issue solved, problem needs to be identified and fixed.

Second, after removing the transaxle switch motor I tested it using the electronic switch on the dash. The transaxle switch moves from 2W to 4WHigh but it will not move to 4W LOW position, only moves between 2H and 4H positions

Looking for recommendations. Does the transaxle switch need to be replaced? What causes the PVH to get stuck? What is the next steps to assure this doesn't re-occur. Thanks in advance, appreciate any suggestions recommendations.

 

over time debris will settle in and around the front driveshaft shift collar inside

you will need to do a complete flush of the transfer case fluid, as the debris will jam the shift collar

 

Thanks cheese man! The front drive shaft collar is in the transfer case, or in the front axel? I'll get the transfer case fluid changed.

 

the shift collar resides inside the transfer case , the front drive shaft output

when you flush the fluid , add about 2 ounces of duralube to the fresh fluid