I have a 2000 Ford Ranger 3.0 Flex fuel 4x4 5spd..On this site I learned how to make mine a live axle which has worked well. A while back I switched to 4x4 and nothing happened. I changed the 4x4 switch as I thought I heard a sizzle behind it when it quit working. The electric shift motor was changed a couple years ago .I can't seem to find the correct diagram for the 4x4 fuses on a 2000 that was assembled in 1999 knowing 98,99 & 2000 should be the same. I figure the 4x4 control module went bad but hope its a fuse. Does a 5 speed and automatic use the same 4x4 Cm ? And where can a person buy a 4x4 CM online, didn't see any on Rock Auto. I found the lone black wire that goes into the shift motor had pulled lose from the plug under the truck and seem to have it plugged back in good. Stuck the truck in the wet clay a couple days ago trying to get out of my yard thinking my mud tires would do it in 2wd but the wife had to pull me out with her Geo Tracker and i'm still hearing from her about it .4x4 lights do blink when turning on the key, and a slight click when switching to 4x4 (sometimes) on first try, doesn't click on 2nd attempt unless I shut the key all the way off and try again.

 

Welcome to the forum

From 1995 to 2000 the 4x4 controller is the GEM, generic electronic module, it runs cab lighting, door locks, wipers, and 4WD if so equipped

There are 4 parts to the system
Dash switch, GEM, 4x4 Relay box, and shift motor

Relay box just has 2 relays inside that power the shift motor, it is usually located with GEM behind the radio

Diagram below

 

Thank you, had a hard time trying to finding the correct fuse location and a schematic. All my fuses check out good . I turn the key forward and turn 4x4 dial and the it clicked about 5 times like its trying to engage but doesn't. Shut the key off and turn forward again and no clicking. When trying again after sitting it will click again like its trying to engage the shift motor but cant.

 

Do the 4WD lights Flash?


Next step would be to pull the shift motor off the transfer case let it hang and then try shifting dash switch to 4high, see if motor moves

Good pictures here: https://www.explorerforum.com/forums...-motor.123542/

The transfer case shift rod is pointed at 2WD(2H) in the picture, you can manually rotate it to 4H, and then to 4L, then back to 2WD(2H)
Between 4H and 4L is NEUTRAL!!!!!!!, directly across from 2H, truck WILL roll away when transfer case is in NEUTRAL so be careful!!!!

It may not rotate all the way if gears inside are not lined up, you may have to rock the truck forward or backwards, to turn drive shafts a bit to get it into 4H and 4L


In the pictures you can see the CONTACT WHEEL inside the shift motor housing
This wheel is how the GEM knows what position transfer case shift rod is in, and GEM can then decide which way to turn the shift rod to get to Drivers selected "gear"
And this wheel tells GEM that motor is turning because contacts will open and close as the wheel turns.
GEM knows what contacts are open and closed for the 3 selections, 2WD, 4high and 4low, so it runs the motor until contact wheel is in the correct position


The 4x4 Relay box is just 2 relays in a box
The electric shift motor has 2 wires for 12volt and ground
Each of these wires is connected to one relay in that box
When the relays are OPEN then BOTH wires are Grounded
So GEM just needs to CLOSE(activate) one relay to send 12volts on that one wire and motor will start
If it sends 12v on "relay one" motor turns clockwise
If it sends 12v on "relay two" then motor turns counter-clockwise
So works the same as power window motors, reverses +/- to get opposite rotation


You know the dash switch works, and it sounds like the GEM is working
So I would see if motor is turning and check the shift rod can move

 

That's what I needed to know what to do next. Will let you know what happens.