Need help with 4x4 switch/module/diagnostics - what now?

[Teal4x4]

Wahoooo! Thanks English Dan - that did the trick.

I took it off the truck, snipped the brown wire and benched the motor. Took it all apart, motor and gearbox to be sure I didn't miss anything. Found the nasty orange plastic bits in there. Made a new sleeve from rubber fuel line that matched the dimensions. See pics.

While I was there I tested the motor, cleaned all contacts, greased up bearing and gear surfaces, re-gasketed it with RTV and re-assembeled.

I was delighted when it worked again first try (wasn't expecting that after all it's taken to get to this point). Guess I didn't need the replacement control modules or switches after all

Thank you all for the great help - I'm good to go

Made an equivalent part from rubber tube:

 

[Andres629]

Yahoo! Good to see you've got it figured out, man!

 

[EnglishDan]

Brilliant!!

 

[ezzywave]

New Guy here.

My '90 Ranger has the exact same symptoms! I measured 5 volts being output from the control module. I was ready to buy a new one and blundered onto this thread while looking for a place to buy it.

Anyways, thanks for saving me a bumcha $$$'s!

 

[Teal4x4]

You're very welcome. That's what this forum is all about