1995 Explorer 4wd questions regarding 4x4 operation and issues Part 2

Hiya Campers.

Continuing on with this 1995 Explorer.

4wd. It has the "ControlTrac" system.

I know there's a lot of info, but no one really has any solution listed. Either they gave up and walked away? Or they fixed it..and never updated.

At any rate:

Transfer case was changed out due to the output shaft bearing being roached. 4wd wouldn't really work, due to miss-match tire size and no speedo input, etc.. It's been like chasing down issues and going down that rabbit hole.

We reused the transfer case motor and sensors off the one from the U Pull yard. Same problem. 4low will kick in and function. 4AWD will initially engage..and then kick out after a few moments of driving.

And it does the 6 flashes of the lights on the dash auto 4wd and 4low...

I'm doing the cheap stuff first. So I picked up a different transfer case motor with the sensors. Also the harness. The harness on ours was mangled with a bunch of cobble repairs before and after the plug to the motor. So that will get changed out from the plug under the seat....to the transfer case. Should only have 1 splice (the one going to the inside of the case next to the output shaft)

I do not think this is the issue. I redid the connections under the truck and for the duration of testing, they are all 100%. But sense I detest soldering a whole bunch of wires and heat shrinking.... Sure 1 wire isn't a big deal. But 6 would kill my back.

Also noted we have NO trouble lights, other then the flashing 4wd lights. I've heard about the ABS sensors causing issues...The hall effect sensors on the transfer case causing problems... The vacuum servo on the front axle. (That last one seems fine?....But I will test if if needed.)

The truck also has a used GEM module. I noted the yellow junk yard paint marker. Looks like this has been an issue with the last owner...

For a 1995 GEM, I would imagine it couldn't be reprogrammed-As it's not an OBD II truck. I did locate a GEM out of a 1995. But the box stated "Automatic" and we have a "Standard". (or would this mean automatic 4wd?)

Just getting tired of cleaning up after someone elses mess. Looks like he (last owner) was having these issues...and was another thing he failed to clue us in on.

Truck runs good otherwise so far. Window motors are a bit flaky however. Been a few times they go down, and it takes a bit to get them up. (Is that controlled by the GEM?) I'd be willing to drop in a GEM from a 1995 Explorer, but the yard didn't have any of the correct year with a standard. Auto's they have a few of...

Suggestions always welcome..... Just trying to deal with it this week. I'm off for vacation to do maintenance on the wifes car (Timing belt and water pump on her Beetle) So I've got some free time to tinker.

S-

Two places I'd look, the auto hubs and the 4x module. Where you at? Someone may have a known good one. I think maybe the 4 low is kicking off the hubs.

No lights tends to be the shift mechanism, so it might be the contact plates on the shift motor (the whole things gotta go)

Two places I'd start

Pauls 4x4 said:

Two places I'd look, the auto hubs and the 4x module. Where you at? Someone may have a known good one. I think maybe the 4 low is kicking off the hubs.

No lights tends to be the shift mechanism, so it might be the contact plates on the shift motor (the whole things gotta go)

Two places I'd start

Click to expand...

Think we might have this one solved. It's had a wiring splice nightmare for a while. I swapped out the harness from under the drivers seat (nice of them to allow an access 'slit' in the carpet...or that might have been the last owner trying to fiddle with it).

And at the same time we replaced the motor and the two sensors. It now engages. (This would be motor #3. One it came with....and I've bought 2 at the local yards) It stayed 'auto 4wd' for around a few blocks after the change over. Before it wouldn't stay engaged for longer then 30 seconds before shutting down with the 6 flashes of the lights on the dash.

S-