1992 Ranger 4x4 issues
 

Just having some 4x4 issues and trying to get it working so I can go wheeling. My 1992 has the 2.9 5 speed with the push button 4x4 and automatic hubs. I have the swap stuff for the hubs to convert it but the 4x4 lights aren’t even glowing and pressing them does nothing. I’m thinking it’s the 4x4 computer but I’m sure it could be a list of things. Anyone have more knowledge on this? It should be the same for years around 90-92.

Welcome to the forum

The auto hubs do engage and disengage the front axles but are not part of the electric shift 4x4 control system, just FYI

The 4x4 system has 3 parts plus its wiring
1. Dash switch, never breaks, well very very rarely has any problems unless you smash it with a hammer, lol

2. 4x4 controller, also lasts a long long time, very reliable, yours uses the same controller as all Rangers, 1994 and older

3. Shift motor on the back of transfer case, often the problem with all year Ford 4x4 systems, Ranger included

First thing to check are Fuses, in the Cab fuse box will be Elec. Shift fuse, 20amp, and ATO fuse, maybe #7, test them or swap them out don't just "look at them"

Next is shift motor, look here: https://www.explorerforum.com/forums...-motor.123542/

You will need to remove the shift motor and test it
In the first pictures you can see the TWO Orange and Yellow motor wires, these are 12volt and Ground wires, this motor works the same way power window motors work:
If the Orange wire is 12volt and the Yellow wire is Ground, then motor turns clockwise
If the Orange wire is Ground and Yellow wire is 12volt then motor turn counter clock wise
So simple polarity reverse to change motor direction
Use your battery to test if motor moves in BOTH directions

The motor/gear setup does have Stops, seen on pictures, so it can only turn so far in one direction, remember that for testing


If fuses are OK and motor works THEN you can move on to 4x4 Controller
Tests seen here: https://www.therangerstation.com/tec...is-1994-older/

There is a system test light on the controller

The 4x4 system has 3 parts plus its wiring
1. Dash switch, never breaks, well very very rarely has any problems unless you smash it with a hammer, lol

2. 4x4 controller, also lasts a long long time, very reliable, yours uses the same controller as all Rangers, 1994 and older

3. Shift motor on the back of transfer case, often the problem with all year Ford 4x4 systems, Ranger included

First thing to check are Fuses, in the Cab fuse box will be Elec. Shift fuse, 20amp, and ATO fuse, maybe #7, test them or swap them out don't just "look at them"

You will need to remove the shift motor and test it
In the first pictures you can see the TWO Orange and Yellow motor wires, these are 12volt and Ground wires, this motor works the same way power window motors work:
If the Orange wire is 12volt and the Yellow wire is Ground, then motor turns clockwise
If the Orange wire is Ground and Yellow wire is 12volt then motor turn counter clock wise
So simple polarity reverse to change motor direction
Use your battery to test if motor moves in BOTH directions

The motor/gear setup does have Stops, seen on pictures, so it can only turn so far in one direction, remember that for testing


If fuses are OK and motor works THEN you can move on to 4x4 Controller
Tests seen here: https://www.therangerstation.com/tec...is-1994-older/

There is a system test light on the controller[/QUOTE]

awesome information. I totally forgot about the fuses in the cab, I think I looked at them the other day but I’ll double check. Might have to get a multimeter to do further diagnostics and projects. There is no test light on the controller unfortunately I think it’s too old. I will take more pictures when I head out today to look

https://cimg4.ibsrv.net/gimg/www.ran...e6f8e3168.jpeg
This it still has a the warranty?
https://cimg5.ibsrv.net/gimg/www.ran...82f1ecce9.jpeg
And I’d assume those top two orange and yellow are the ones you are taking about?
https://cimg8.ibsrv.net/gimg/www.ran...2043d6f6d.jpeg
Pictures

Testing
 

https://cimg8.ibsrv.net/gimg/www.ran...c0e0b8288.jpeg
I tested the two cables leading into the motor and didn’t hear movement, should I be testing the other two going into the other section? I put one side on positive and one negative on battery and had no movement

Yes, those are the wires, and you also need to reverse them to test motor to move in both direction but you should have heard it trying to move

No, on the other 5 wires, they are "sensors" they tell the 4x4 controller what position the transfer case is in, 2WD, 4High or 4Low

That picture at the top is NOT the 4x4 controller, it looks like the back of the engine computer, has a 60-wire plug in?
4x4 controller should be behind drivers seat , behind a plastic panel

New 4x4 motor on the way.
 

Got the motor on the way for the 4x4 now I’m just going to try and find that computer. Will update when I do.

Should look like this: https://www.therangerstation.com/tec...4wd_module.JPG

and this: https://www.therangerstation.com/tec...wd_module2.JPG

Same unit from 1983 to 1994

People often thought it was an amplifier because of the heat sink(fins)

It works!
 

4x4 worked right after the new motor. Easier than expected too

Good work

Thanks for the update and THE FIX