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Car Forum / Ford / Ford Explorer / May 2005

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4wd Dash Buttons Not working...please help a newbie....

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Slamminhoyt - 16 May 2005 01:35 GMT
I FINALLY got my brother’s Explorer...a 1994 model for a GREAT price.
The thing is bullet proof. It is a 4wd model, but the 4wd hasn’t
worked since he has owned it (five months) and he doesn’t have much
"mechanical ability" so he just left it alone.

You push the actuator buttons and nothing happens. I assumed it was
the actuator switch and changed that with one from a friend’s parts
truck that we know it worked in.  But it still won’t work. I got out
the current tester and checked the plugs that the actuators 8 blades
go into.

Four of them light up...but the other four don’t...  should there be
power to all of them? Is it a possibility that there is a wiring
problem "in the dash" or to the transfer case or actuator motor???

Thanks a lot...I appreciate all of the help you can give a newbie!  

Jerod M.
Ashton Crusher - 16 May 2005 02:18 GMT
>I FINALLY got my brother’s Explorer...a 1994 model for a GREAT price.
>The thing is bullet proof. It is a 4wd model, but the 4wd hasn’t
[quoted text clipped - 14 lines]
>
>Jerod M.

Go here...

http://draco.acs.uci.edu/explorer/tcase.html
Ulysses - 16 May 2005 17:42 GMT
> >I FINALLY got my brother's Explorer...a 1994 model for a GREAT price.
> >The thing is bullet proof. It is a 4wd model, but the 4wd hasn't
[quoted text clipped - 4 lines]
> >the actuator switch and changed that with one from a friend's parts
> >truck

Why is it a "parts" truck?  Wrecked?

that we know it worked in.  But it still won't work. I got out
> >the current tester and checked the plugs that the actuators 8 blades
> >go into.
[quoted text clipped - 10 lines]
>
> http://draco.acs.uci.edu/explorer/tcase.html

And if all of the wires check out ok there is a strong possibility that the
servo motor is just stuck.  It happened on both my '91 and '92.  I removed
the servo motor (had to cut the single brown wire going to the transfer case
and solder it back together when done), took it apart, cleaned it thoroughly
with carburator cleaner, lubed the bushings with motor oil, and lubed the
worm gears with vaseline (it's a long way to the auto parts store from
here--was all I had on hand).  It has been working fine since (6 months or
so).  Mark everything before disassembly so you'll get it back together the
way it was.  Those wires you mentioned that had no voltage to them might be
the indicators for 4H and 4L and would not have power to them unless the
transfer case was in those positions.  I should also add that the motor
brushes have little slots that the brush wires fit into to facilitate
reassembly.  Position the rotor between the brushes and release the wires
with a small screwdriver etc. and check to make sure they are not stuck.

The other method that has been mentioned here many times is to tap (gently)
on the servo motor while someone pushes the 4X4 button.  Sometimes it will
get it moving again.

Then, after you get it all working again, you can look into getting manual
locking hubs because the autohubs have a very high failure rate.  But then
you are lucky enough to have a "parts" truck available.

.http://www.accessconnect.com/superwin.htm
Bob - 18 May 2005 00:38 GMT
>>>I FINALLY got my brother's Explorer...a 1994 model for a GREAT price.
>>>The thing is bullet proof. It is a 4wd model, but the 4wd hasn't
[quoted text clipped - 48 lines]
>
> .http://www.accessconnect.com/superwin.htm

Is it possible to get rid of the servo motor and install a lever to
shift the transfer case?  my motor's been flaky lately. I'm thinking of
replacing it with a lever (and replacing the auto hubs with manual while
I'm at it.) It's a '94 XL with auto trans.
Ulysses - 18 May 2005 17:45 GMT
> >>>I FINALLY got my brother's Explorer...a 1994 model for a GREAT price.
> >>>The thing is bullet proof. It is a 4wd model, but the 4wd hasn't
[quoted text clipped - 53 lines]
> replacing it with a lever (and replacing the auto hubs with manual while
> I'm at it.) It's a '94 XL with auto trans.

I've read several posts over the years about folks considering some kind of
manual shift instead of the motor, but I don't recall having read about
anyone who actually did it.  The good news is that according to the Hayne's
manual some of the manual and electronic shifting Explorers use the same
transfer case (Borg-Warner 13-54) so it may be possible to find the manual
shifting mechanism on a junker and install it but I suspect if you have an
automatic transmission it may present problems as it is unlikely that Ford
would put a manual 4WD shift on a truck with an auto trans.  There was also
another transfer case used (BW 44-05) that apparently was electronic
controll only.

Aside from that I have removed my servo motor so I could shift into 4WD when
it was either that or not go anywhere.  I drove through some serious mud
with it exposed and it didn't seem to hurt it any, but I wouldn't recommend
doing it for any length of time without sealing the transfer case again.
Bob - 19 May 2005 00:12 GMT
>>>>>I FINALLY got my brother's Explorer...a 1994 model for a GREAT price.
>>>>>The thing is bullet proof. It is a 4wd model, but the 4wd hasn't
[quoted text clipped - 108 lines]
> with it exposed and it didn't seem to hurt it any, but I wouldn't recommend
> doing it for any length of time without sealing the transfer case again.

Thanks for the information. Sounds like it's not so easy as just
removing the motor and replacing it with a lever.

Where I work we had a fleet of Ford Broncos and they were all auto
transmission with the manual transfer case shift lever. But I've never
seen an Explorer configured that way.

I'll probably remove and clean, lube and replace the brushes(?) on the
motor and maybe it'll last another 10 years. Thanks again.
Ulysses - 19 May 2005 00:39 GMT
> >>>>>I FINALLY got my brother's Explorer...a 1994 model for a GREAT price.
> >>>>>The thing is bullet proof. It is a 4wd model, but the 4wd hasn't
[quoted text clipped - 111 lines]
> Thanks for the information. Sounds like it's not so easy as just
> removing the motor and replacing it with a lever.

It would present some complications to try and juryrig something.  For one
thing the 4WD position indicators are on the servo motor.  I think the
amount of turning on the transfer case shaft is around 90 degrees so some
kind of gearing would probably be necessary in order to operate it from
inside the truck.
Or just take off the servo motor and put a little trap door in the floor and
someone in the back seat could reach down and turn it with a pair of pliers
;-)

> Where I work we had a fleet of Ford Broncos and they were all auto
> transmission with the manual transfer case shift lever. But I've never
> seen an Explorer configured that way.

Actually I'm surprised they did the Broncos that way.  Everything now is
buttons, buttons, and more buttons.  They even put electric windows in
pickups that only have two windows and it's close enough to reach over to
roll it up or down.  Being the kind of guy who keeps cars for a long time I
just look at all of this electric stuff as more things to go wrong.

> I'll probably remove and clean, lube and replace the brushes(?) on the
> motor and maybe it'll last another 10 years. Thanks again.

The motors get very little use so chances are the brushes are still fine.
The first time mine got stuck I just sprayed WD-40 inside the servo motor
and it worked for about 6 months.  On my wife's '92 I used the WD-40 and
that was a couple of years ago.  Still works.  Now I try to remember to push
the 4WD button every couple of days to prevent it from getting stuck again.
Meanwhile I never drive in the rain without a socket set and a tarp or
something to lay on in case it fails and I have to crawl underneath and
remove the servo motor again.  But at least it's possible.  Let me know if
you find a good way to switch to manual.  To me it would be a big
improvement.
Bob - 21 May 2005 00:41 GMT
>>>>>>>I FINALLY got my brother's Explorer...a 1994 model for a GREAT price.
>>>>>>>The thing is bullet proof. It is a 4wd model, but the 4wd hasn't
[quoted text clipped - 175 lines]
> you find a good way to switch to manual.  To me it would be a big
> improvement.

I'll definitely try the WD 40. The push button 4 WD is a gimmick I could
live without, just another thing to go wrong (usually at the worse
possible time). I'm putting manual hubs on it soon, I'm not gonna wait
till one of the auto hubs fail. (Happened to me in a Bronco on soft
beach sand, wasn't fun.)
Bob - 21 May 2005 00:53 GMT
> Where I work we had a fleet of Ford Broncos and they were all auto
> transmission with the manual transfer case shift lever. But I've never
> seen an Explorer configured that way.

>>>Actually I'm surprised they did the Broncos that way.  Everything now is
buttons, buttons, and more buttons.  They even put electric windows in
pickups that only have two windows and it's close enough to reach over to
roll it up or down.  Being the kind of guy who keeps cars for a long time I
just look at all of this electric stuff as more things to go wrong.<<<

These Broncos were low bid bulk purchase for the US Government. They
probably buy 100 at a time. All were manual shift transfer case (but
auto transmission) vinyl interior(you could hose it out with no
problem), crank windows, AM radio, no console. Great truck for the work
I do (Geologist).
 
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