Broken transfer case?

[CamTheHedgehog]

Hey all. So I recently bought a new transfer case shift motor for my truck, as the 4x4 wasn’t working and I took the motor off and it would not move. 2003 ranger edge. Supercab, 4L, 4x4. It came today and I quickly installed it. I went to test it on some loose gravel, and sure enough it was working. I then took a tight u turn, while still in 4x4, and then heard 2 rather loud clunks. Now my 4x4 does not work. I can shift in and out fine, and I hear the motor clicking, but I can spin tires on gravel and nothing happens. Is my transfer case doomed?

also, I’m currently 1000 miles away from home and I’m leaving to return in a week and a half.

 

[ericbphoto]

I would check passenger side axle shaft u-joints and both front hubs first.

 

[RonD]

Could be chain in transfer case or front axle
Did you try 4Low?

Have someone look under front drivers side of truck to see if front drive shaft is spinning while you roll forward in 2WD, it should if axles and differential are OK

If it doesn't then put it in 4WD and check again, if it spins now transfer case is OK


You have an OPEN differential on the front, so if one axle is not connected to wheel then no 4WD

 

[CamTheHedgehog]

Could be chain in transfer case or front axle
Did you try 4Low?

Have someone look under front drivers side of truck to see if front drive shaft is spinning while you roll forward in 2WD, it should if axles and differential are OK

If it doesn't then put it in 4WD and check again, if it spins now transfer case is OK


You have an OPEN differential on the front, so if one axle is not connected to wheel then no 4WD

I believe 4lo still works, at least the gear reduction part. And I will recruit my brother tomorrow to do that with me.

 

[CamTheHedgehog]

I would check passenger side axle shaft u-joints and both front hubs first.

Do you mean CV joints? Also I have a 2003 so no locking hubs

 

[ericbphoto]

Do you mean CV joints? Also I have a 2003 so no locking hubs

Ah. Yes. Sorry. I was thinking older trucks with TTB. CV joints should be less susceptible to damage from tight turns, though.
Best thing would be to get the front end up on jack stands (engine off). Crawl under and start looking at stuff and rotating things by hand to see what is or isn’t turning with the transfer case in 4wd.

 

[CamTheHedgehog]

Ah. Yes. Sorry. I was thinking older trucks with TTB. CV joints should be less susceptible to damage from tight turns, though.
Best thing would be to get the front end up on jack stands (engine off). Crawl under and start looking at stuff and rotating things by hand to see what is or isn’t turning with the transfer case in 4wd.

Yeah- that’s my plan for this morning once I’m done with my other stuff.

 

[CamTheHedgehog]

UPDATE!
I got it up in the air, spun wheels in 2wd, it rotated front driveshaft. Put it in 4wd with the switch, and driveshaft still spun with a slight ticking from the t-case.
Took the motor off, used some vice grips to rotate the shaft to 4wd and spun the wheels.
Driveshaft didn’t spin.

After further investigation,

The stupid f@$*#&g DORMAN REPLACEMENT SHIFT MOTOR I bought doesn’t turn far enough to engage 4x4 hi!

hey, at least I’m not dumping $500+ on a new t-case!

 

[CamTheHedgehog]

Also- does an OEM ford part for the shift motor still exist?

 

[RonD]

It may just need to be adjusted

The top plate on the shift motor should have 3 screws and slotted holes, like this one: https://i5.walmartimages.com/asr/3d0eb993-b7c2-4b74-89f1-2e57cb18c4f7.30fa4f439959d0e7dfc7183bfb040555.jpeg?odnHeight=450&odnWidth=450&odnBg=ffffff

The top plate has the sensors/contacts that tells the 4x4 Controller the position of the shift rod
When to stop turning it when it reaches the correct location

Contacts and contact plate seen in this article: https://www.therangerstation.com/tech/rebuilding-a-ford-transfer-case-shift-motor/

Turn OFF key
Loosen the 3 screws and turn the top cover towards the direct you want the shaft to move farther
Tighten strews
Try shifting again to see if it now goes far enough to 4high position

Generally speaking the average of transfer case and shift motors positioning will be plug and play
But not every time, which is why there is an adjustment
If your new motor doesn't have this adjustment send it back and get one that does

 

[Josh B]

Do you still have the original shift motor? I think they mostly go out because the contacts inside get dirty.
Mine didn't work when I bought it so I replaced it, but kept the original, eventually cleaning it up to use as a spare

You can likely find a lightly used OEM one at the wrecking yard

 

[CamTheHedgehog]

Do you still have the original shift motor? I think they mostly go out because the contacts inside get dirty.
Mine didn't work when I bought it so I replaced it, but kept the original, eventually cleaning it up to use as a spare

You can likely find a lightly used OEM one at the wrecking yard

I do- tried cleaning it up today and no dice. I have the version where you can’t get to the wiper contacts without destruction, and thus I don’t think I can get to the (probably) problem.

 

[CamTheHedgehog]

Also wanted to ask this.
Quite often on here and elsewhere I see discussions about the 8th brown wire for the TCSM connector, that goes to the clutch/synchro that allows you to shift-on-the-fly. My motor did not have that when I removed it, do some years not have it or am I missing something?

 

[Josh B]

Also wanted to ask this.
Quite often on here and elsewhere I see discussions about the 8th brown wire for the TCSM connector, that goes to the clutch/synchro that allows you to shift-on-the-fly. My motor did not have that when I removed it, do some years not have it or am I missing something?

Our vehicles are about 10 years apart Cam.
I am not so knowledgeable on those matters sir, but it is a good question, and there are others here who are.
Hopefully in good time they will chime in, I certainly wish you well with it.

 

[CamTheHedgehog]

No worries! You all are wonderful- thinking about donating for the supporting member badge- I’ve already gotten $10 worth of info here!