1993 Ford F150 4x4, 302, automatic, 186000. I use 4WD often when needed on muddy construction sites. Occasionally it will not engage when you press the button on the dash. I have had to tap the motor on the transfer case lightly before the 4wd would engage. After the tap, no problem. This would happen every few months, depending on how much I used the 4wd. On each occasion when I pressed the botton on the dash, I would hear the relay under the dash give off a low clicking sound. Normal right? Well now when I press the botton, there is no clicking sound from the relay and the 4wd does not engage. I suspect the relay has worn out. Now I'm fairly confident with mechanical stuff, but electrical components slow me down a bit. How do I know what part needs to be replaced? I dont even know where it is because it doesent make a sound anymore. Need help quick because I need the 4wd.

 

I'm looking at 1992 diagnostics...have you checked the fuses and maybe #18 in particular?

 

i checked the fuses first, and they appear to be fine. One of them is not transparent though. Big and metallic casing. I cant tell if it is blown except that there are other features that this fuse controls and they all work. In fact, there are two fuses listed on the fuse panel that deal with the 4wd. both of them also service other features on the truck, and all those features work.

 

The actuator on the case is probably wasted or the brushes glazed. I'd check for power at the actuator and if it checks out, I'd pitch the actuator for a new one.

Knuckles posted a fix on those Fords a while ago with link.

 

The Knuckles thread:

http://forum.doityourself.com/showth...nsfer+and+case

If you would like to see some of the diagnostics for a 1992 from Alldata, Email me with your address.


Description and Operation

The Electronic Shift Control Module is powered at all times through Circuit Breaker 12 of the Fuse Panel to retain its memory capability. Fuse 18 provides power for the switches and the Electric Shift Motor when the Ignition Switch is in RUN. Fuse 10 provides power for nighttime illumination of the Electronic Shift Control Switch.

When the Electronic Shift Control Switch is placed in the 4x4 or LO position, the Electronic Shift Control Module analyzes information from the Shift Postion Sensors to determine their current positions. The Module also analyzes information inputs from the Transfer Case Speed Sensor and the Automatic Transmission Switch. The Electronic Shift Control Module then activates the Transfer Case Motor to produce the desired shift, and the 4x4 indicator lights up.

ELECTRONIC SHIFT CONTROL
The Borg-Warner 13-56 electronic shift transfer case transfers power from the transmission to the front and rear axle assemblies when electrically actuated by either of the two switches mounted in the push-button control panel. The electronic control module will analyze information from the transfer case shift position sensor to verify its current position. The electronic control module also analyzes input information from the speed sensor and the clutch interlock switch (M/T) (or neutral safety switch (A/T) depending upon transmission application). When all conditions are met, the electronic control module will command the electronic shift motor to execute the desired function. After the shift occurs and the motor is turned off, the electronic control module resumes looking at the inputs from the shift position sensor to determine if the transfer case is in the position selected by the operator. The electronic control module illuminates the push-buttons in the control panel indicating that the desired function has been completed.

If you need a new motor try www.fordpartsonline.com or www.parts.com
Should be able to save $100 or better.

 

ill check it out!