Hello,

about 1.5 months ago, I turned my truck off while it was in 4wd. I'm unable to put it back into 2wd. I've had it checked out and I'm sure it's the control module that is the issue - wiring, fuses etc all check out and I see this is a common issue with this model year. Usually most people have the opposite problem of not being able to engage 4wd though. I'm happy to replace the control module, however the part is on backorder and I may not be able to get my hands on it til April. ( I checked with Silver State Ford)

Since we've gotten about 100" of snow since then, I've never really needed to switch it off, but now that it's close to Spring and I probably won't need 4wd unless I get caught in a freak mudslide, I want to know:

1. Aside from poor handling and awful MPG, are there any long term effects to driving in 4wd on dry surfaces? My normal driving is a short 18 mile round trip commute to and from work.

and

2. If so, is there a way to manually disengage 4wd without the assistance of a working control module? Hopefully this is something that I can do and something I don't have to pay for, which ideally would be avoided

much appreciated!

 

Yes, you are correct the module is an issue.
No, not really a way to shift transfer case without removing shift motor and manually shifting the transfer case, but then you have an issue because shift motor is set at 4WD high so won't go back on because shift shaft is now at a different angle.

Your transfer case(BW1354) doesn't have the internal clutch like the BW4405 used in all wheel drive models so driving on dry pavement can put a strain on transfer case internals.
That being said it is more of a long term issue IMO, but............it is your truck so your bill to pay if transfer case breaks, my opinion is worth spit, lol.

You could drop the front drive shaft, probably the easiest thing to do to be worry free, I haven't done that on an '02 so not sure whats involved.
Make sure to mark it's orientation on both ends if you do this.