Yo,
http://broncozone.com/topic/23049-e40d-transmission-issues/
Works for me, try it again. Some of this set of tests includes use of Ford's old Break-Out Box. See below for info.
The aftermarket sensors are of poor quality. Try one from a local yard from 92 to 95 Bronco if yard will give money eyes back guarantee.
Have a local Ford dealer to purchase the VSS?
Catalog Results / 1994 Ford Bronco Parts / Part Details
Part Name: ABS Sensor
Brand: Motorcraft
Part Number: 2L373(BRAB-130)
Price: $37.20
Quantity: 1
Or Select a dealer for their prices and availability
Part Description: Located in rear axle housing, used as ABS sensor.. Ford changes description often and use, for 92 to 96 Bronco, the VSS is used for the 4WABS, psom, & through the PCM for e4od control and cruise control.
Quantity Per Vehicle: 1
Package Quantity: 1
Weight: 0.20 lbs
Dimensions: 6.00 IN x 4.00 IN x 0.00 IN
http://www.fordparts.com/Commerce/PartDetail.aspx?n=EXvnmLepXEl4j%2bCyX9WzjA%3d%3d&id=356575808&m=2&search=true&year=1994&make=Ford&model=Bronco
633 4x4 switch closed self test indicates that the transfer case 4x4 switch was on. Probably caused 691 4x4 Low circuit failure as well if the transfer case is operating OK.
Or,
this set of tests includes use of Ford's old Break-Out Box; so, as I mentioned in another thread here; In place of the break-out box, go to the EEC connector pin instead; Substitute EEC connector pin Number for breakout box number
EEC Connector Pin Diagram
Source: by Fireguy50 (Ryan M) at
http://web.archive.org/web/20131229163930/http://oldfuelinjection.com/images/eec04.gif/
EEC Connector Pin LEGEND Bronco & Ford Truck & Van: 4.9, 460, 5.0, 5.8;
Source: by Ryan M (Fireguy50) at Ford Fuel Injection
http://api.viglink.com/api/click?format=go&jsonp=vglnk_146159523966511&key=6ed47b392b9edfe394b9e89b72717104&libId=ing3zwkl01000bgv000MAb2wnuoon&loc=http%3A%2F%2Fwww.fullsizebronco.com%2Fforum%2F21-noobie-bronco-tech-questions-flame-free-zone%2F399882-code-654-a.html&v=1&title=Code%20157...%20-%20Ford%20Bronco%20Forum&txt=Ford%20Fuel%20Injection&out=http%3A%2F%2Fweb.archive.org%2Fweb%2F20131029020805%2Fhttp%3A%2F%2Foldfuelinjection.com%2Ftruckpinouts.html
DTC 691 4x4 selector fault (observed in Continuous Self-Test) is set when a stored Kam value for N/V (engine rpm/vehicle speed) is compared to a calculated N/V for the current switch position and driving condition. If these checks disagree, DTC 691 is set.
Possible Causes:
Damaged 4x4 Low switch or 4x4 selector lever position.
Shorted harness.
Damaged PCM.
Internal damage to transfer case.
Is the 4x4 lever positioned in 4x2/4x4 high?
Yes GO to TB4.
No RERUN KOEO Self-Test with positioning selector in 4x2/4x4 high.
TB4 CYCLE THE APPROPRIATE CIRCUIT:
(4x4 LOW)
Key off.
Disconnect Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary.
Install breakout box, leave PCM disconnected.
Key on, engine off.
For 4x4 Low circuit:
Measure voltage between Test Pin 12 and Test Pin 40/60 at the breakout box while moving the 4x4 select lever between 4x2 and 4x4 Low several times.
For TCS circuit:
Measure voltage between Test Pin 41 and Test Pin 40/60 at the breakout box while cycling the transmission control switch several times.
Does the voltage cycle?
Yes REPLACE PCM.
No REMOVE breakout box. RERUN Quick Test.
For a driveability symptom only: GO to TB7.
For a DTC: GO to TB5.
TB7 CHECK OUTPUT DRIVER SIGNAL
Note: When entering this Test Step with a symptom or a Self-Test Pass code, first disconnect Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, loose wires, etc. Service as necessary.
Key off.
Breakout box installed, PCM disconnected.
Key on, engine off.
For 4x4 Low circuit:
Switch disconnected.
Measure voltage between Test Pin 12 and PWR GND at the breakout box (ohmmeter negative probe).
For TCIL circuit:
Measure voltage between Test Pin 32 for E/F/B Series Trucks, Test Pin 14 for 3.2L SHO or Test Pin 55 for all others and PWR GND at the breakout box (ohmmeter negative probe).
Are both voltage readings at least 2.0 volts?
Yes GO to TB8.
No INSPECT for damaged indicator bulb (4x4 Low LED or TCIL) or damaged fuse in fuse panel. If OK, SERVICE open circuit. REMOVE breakout box. RECONNECT all components. RERUN Quick Test.
TB8 CHECK CONTINUITY OF THE 4x4 LOW OR TRANSMISSION CONTROL SWITCH HARNESS
Key off.
Breakout box connected, PCM disconnected.
Appropriate switch disconnected.
For 4x4 Low circuit:
Measure the resistance between Test Pin 12 at the breakout box and 4x4 Low circuit at 4x4 Low switch touch drive module vehicle harness connector.
For TCS/TCIL circuit:
Measure the resistance between keypower at the fuse panel (fuses) (ohmmeter positive probe) and power side of transmission control switch vehicle harness connector (ohmmeter negative probe).
Measure the resistance between Test Pin 41 at the breakout box and signal side of transmission control switch vehicle harness connector.
Are both resistances less than 5.0 ohms?
Yes GO to TB9.
No SERVICE open circuit(s). REMOVE breakout box. RECONNECT all components. RERUN Quick Test.
TB9 CHECK HARNESS CIRCUIT(S) FOR SHORTS TO POWER
Key off.
Breakout box installed, PCM disconnected.
Appropriate switch disconnected.
For 4x4 Low circuit:
Measure resistance between Test Pin 12 and Test Pin 37/57 at the breakout box.
For TCS/TCIL circuits:
Measure resistance between Test Pin 41 and Test Pins 37/57 at the breakout box.
Measure resistance between Test Pin 32 for E/F/B Series Trucks, Test Pin 14 for 3.2L SHO or Test Pin 55 for all others and Test Pins 37/57 at the breakout box.
Is each resistance greater than 10,000 ohms?
Yes REPLACE damaged switch, either 4x4L range switch or transmission control switch (TCS) due to DTC received. REMOVE breakout box. RECONNECT PCM. RERUN Quick Test.
No SERVICE short circuit(s). REMOVE breakout box. RECONNECT all components. RERUN Quick Test.
....
Try locking the Hubs and run the Bronco back and forth a few times .. should operate 4x4 at least once a month to **** the Hubs and case.
Here it is...
"Do not drive on hard surface roads in 4-wheel drive because it can cause drive train damage. Do not move the vehicle if the hubs are anywhere between “FREE” and “LOCK” or it will damage the hublocks. Driving with only one hublock engaged can cause drive train damage. Driving with the hublocks in ”FREE’’ and transfer case in 4-low can cause drive train damage. To ensure lubrication of the front axle, engage hublocks for a minimum of one mile monthly..."
Source: by Warn®