So I have a 91 4wd 2.9L
currently when i try to engage 4wd it does not happen. I hear the shift controller clock behind the seat but i don't think the motor on the TC is engaging. Any ideas other than replacing the shift motor itself? I have one on order. Just thought some of you guys might know.

Thanks!!!

 

Welcome to the forum

There is a 20amp fuse in the engine fuse box that powers the shift motor, I don't have a diagram for 1991 so not sure of the number, but have a look at the 20amp fuses

Tap on the shift motor with a hammer, it will usually start working again, but its temporary

The shaft motors fail from disuse usually, not over-use
The electric motor's brushes corrode so motor won't turn any more, tapping on the case can get them in contact again
Sometimes these sit for 11 months a year without being used

After you get it working make a habit of shifting from 2WD to 4High then 4low and back to 2WD once a month, just sitting in the driveway
This keeps the rotor and brushes clean, and keeps the lube inside the shift motor gear box spread out

 

Copy that, will try in the morning. No 20A in the engine box. All the fuses in there are good. Took a look at the controller behind the seat it clicks but nothing to the motor. Also the lights at the 4x4 and low range don't light up.

 

Most common issue 1994 and earlier is the shift motor
When you select 4wd and hear a "click", then the switch and controller are most likely working

There is a test button on the 4x4 controller, white button
Key on, engine off
Press the button
If red LED next to it flashes then controller self test shows its OK
If LED comes on and stays on then controller did NOT pass self test so could be bad
If no LED at all then its bad, OR ............no power


You can pull out the shift motor and use 12v battery to see if you can get it to move
You will see the Yellow and Orange wires that run to the motor part, the other wires are for position "sensor", tells controller where transfer case shift rod is pointed

The motor part is the same as power window motor
Yellow wire +
Orange wire -
And motor turns one way

Yellow wire -
Orange wire +
And motor turns the other way
i.e. window up and window down

The shift motor gear box does have a mechanical stop so motor can only turn it so far, it is possible for motor to hit the stop and then get stuck there, not common but possible
If you can get the motor to work, using battery, and run it back and forth a few times it might clean up the brushes and rotor enough to use it again
Rebuilding it is better, article on that seen here: https://www.therangerstation.com/tec...e-shift-motor/

You should look thru it just to see how things work

There will be a Brown wire for activating the electric clutch inside the transfer case, its often not pinned inside the 8 pin connector, so not an issue when swapping or removing the shift motor
If it is pinned in the shift motor connector, you can use a small screw driver to release the pins and then put it in the new connector, seen here: https://www.explorerforum.com/forums...n-wire.344577/

 

Thanks for all the tips guys! I got it going after a little fonz magic with a mallet. The motor hasn't been engaged in 3 years. So it is still intermittent. I have a new motor being delivered via Amazon tomorrow and it should be a pretty easy swap!

God I really love and miss my old manual t-case.

 

Good work

Thanks for the update and THE FIX

Yes, manual ANYTHING is disappearing fast