4X4 low

[racer2012]

 My 96 won't shift into 4 low .. I've checked all the fuses and swapped out the shift module and switch .. Shifts in and out of 4 High with no problems .. And the lights in the cluster and switch indicate properly .. Just will not shift into 4 Low ..No matter what position the shifter is in either .. 

 Looking at a wiring diagram and already swapping out the switch and module it points to the motor position sensor ... 

 I don't have a shop manual so I don't have any trouble shooting trees to follow... I'm stuck for now .. Is that sensor inside the X-fer case ? 

Also by looking at the diagram it looks like the shift module sends power to the switch and the Hi or Low button sends that power back to the module to drive the motor and the position sensor shut it off whens where it's supposed to be ...

 I'm under the rock on this one .. 

 

[miesk5]

yo RACER,

EDIT;

I had an issue C&P info here and ended up with 1/2 page of blank space between paragraphs.

And I could not edit to get all this in proper order to answer your most important Qs

And I kept getting an error message; "You are not allowed to use that image extension on this community"  I had a few images here and the friggin error messsage did Not indicate the Image not allowed!

Electronic Shift Control System
This system consists of a two-switch control system, an electronic control module, an electric shift motor with an integral shift position sensor, and a speed sensor.

Switch Control System
There are two control switches located on the upper right corner of the instrument panel for fingertip shift control. The two switches are mounted horizontally and are identified as "4x4" and "LOW RANGE." Two indicator bar lamps are located in the instrument cluster.

When either of the two switches on the instrument panel control are depressed, the first thing that happens is that the electronic control module receives input from the transfer case shift position sensor to verify what position the transfer case is in (2H, 4H or 4L). Next, the electronic control module looks at the speed sensor and the park/neutral position switch or clutch pedal position switch (depending on transmission type). If all conditions are correct to allow the desired shift, the electronic control module will tell the electric shift motor to execute the shift. After the shift has been made and the electric shift motor is off, the control module again looks at the shift position sensor to make sure the proper shift has been accomplished. Finally, the dash indicator light and the push-button light on the control panel will be illuminated by a signal from the electronic control module indicating the desired function has been completed.

Electronic Control Module
The electronic control module, located on the passenger side, controls the operation of the transfer case in response to inputs to the push-button control by the vehicle operator, the speed sensor, shift position sensor and the park/neutral position switch.

Speed Sensor
The speed sensor, mounted on the rear of the transfer case, tells the electronic control module the speed of the vehicle to allow range shifts (in or out of 4L) to occur.

Shift Position Sensor
The shift position sensor, an integral part of the electric shift motor, tells the electronic control module the shift position of the transfer case.

Electric Shift Motor
The electric shift motor, mounted externally at the rear of the transfer case, drives a rotary helical cam which moves the 2W-4W shift fork and 4H-4L reduction shift fork to the selected vehicle drive position.
 


Borg-Warner 13-56 Electronic Shift Transfer Case
Item Part Number Description
1 7A039 Extension Housing
2 7B214 To Rear Axle
3 7A195 Transfer Case
4 7E063 Skid Plate
5 7B214 To Front Axle
6 7G360 Transfer Case Shift Motor
7 � Wiring Connector Mounting Bracket (Part of 7G360)
8 � Shift Position Sensor
(Part of 7G360)
9 87675 Fill Plug
10 7B214 Case Yoke
11 7F239 Speed Sensor
12 � Wiring Harness Connector
(Part of 7G360)
13 87675 Drain Plug


 


1996 Bronco Owners Guide (Manual) by Hiller Ford

http://hillerford.com/resource_library/owner_manuals_pdf/1996_owner_manuals_ford/96bronco.pdf

4x4 SYSTEMS-TOUCH DRIVE

begins on Page 197

To shift from 4x4 to 4x4 LOW RANGE:

Stop the vehicle and place the automatic transmission in NEUTRAL or depress the clutch on vehicles with a manual transmission. Push the LOW RANGE button on the instrument panel to shift the transfer case from 4x4 to 4x4 LOW RANGE. Both the 4x4 and LOW RANGE lights are now lit.

NOTE: The vehicle must already be in 4x4 before pushing the Low Range Button.

To shift from 4x4 LOW RANGE to 4x4:

Stop the vehicle and place the automatic transmission into NEUTRAL or depress the clutch on vehicles with a manual transmission. Push the LOW RANGE button on the instrument panel to shift the transfer case from 4x4 LOW RANGE to 4x4.

 on the beach, I sometimes need to rock the Breonco back & forth; or turn engine off and try again; but this is w/manual transfer case & manual hubs.

1356 Electric Shift Motor Troubleshooting & Repair (travel stops {SHIFT POSITION SENSOR})
Source: by Richard C (Bigric, Money Pit)

Four Wheel Drive (4X4) General Information, Operation & Troubleshooting TSB 92-1-8 for 92 & Prior Year Bronco, F Series & Ranger; Includes Electric Shift On The Fly (ESOF) Troubleshooting after 92 & Hub Operation
 

by Ford via Chilton

http://content.chiltonsonline.com/TSB/displayTSBHandler.ashx?assetID=36059&key=6kAUBD5BruOJf%2f3tgozUqjXM3RdbjcQqW4sVWiE%2fp2IojfpfKqM07dr61%2bQAWHtTZr4ceHaQGlj8NylACcNZ4qedMqy4JdYyAXN5akgfkpHUz4aCpJyaaA%3d%3d

Page 10

If the vehicle won’t shift into 4L, check the speed sensor and the transmission interlocks (neutral or clutch in). Also check the 4L switch (C3) to see if the module is getting a signal. Be sure to check for corroded connections.

It may seem strange to say this, but you should ask the owner/operator if this was the first time the vehicle was ever shifted into 4L. Many vehicles are purchased and operated for considerable periods of time before a shift to 4L is made. The problem may be a defective part that was there from the beginning.

1356 Electric Shift Speed Sensor pics in a 96 by drinkbrew (Jason)

here is a pic I have with the speed sensor hole exposed, it's the one in the red circle, my problem is I broke the other wire (blue circle) that goes to the magnetic clutch and haven't figured out how im going to fix that yet.

http://i71.photobucket.com/albums/i160/drinkbrew/truck/E4OD.jpg

http://i71.photobucket.com/albums/i160/drinkbrew/truck/1267164582.jpg

1356 Electric Shift Motor Typical Failures & Prevention; "...Most units fail because of water or mud intrusion. Carefully inspect motor boot or protective coverings. Be sure connector seals can keep water and debris out. Check wiring harness and connector. Replace or repair wiring as necessary. After installation, periodically select 4-wheel drive mode to ensure operation when needed..."
Source: by CARDONE®

The vehicle's speed must also be within specified limits as determined by the transfer case speed sensor (3 mph or under)...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)....read more; Miesk5 Note Ford Part Number is 7f293, speed sensor
 by Vincent

1356 Electric Shift Speed Sensor Replacement Information & in an 89; "...took about 45 minutes to remove the yoke, tail housing, and solder/splice/heat shrink the new sensor in place..."
Source: by kf4amu (Will H, The Beast)

also, for posterity;

If the vehicle is brought to the shop in 4L with the  report that it won’t shift back to 4H, your first check is to follow the proper sequence of being stopped and having the vehicle in neutral (or clutch in) when pushing the switch. If this doesn’t do the trick

check the 4L switch and the motor position sensor.

Ford Four Wheel Drive System Excerpt from Bronco/F Series Owner's Guide in a 96
Source: by Ford via BroncoJoe19 at Ford Bronco Zone Forums

http://broncozone.com/topic/13576-howto-shift-into-and-out-of-4x4-manual-and-auto-hubs/

1996 Bronco-F-Series Workshop Manual by diesel-dave.com (PARTIAL)

http://www.diesel-dave.com/vehic/manual/stj/stjleft.htm

 

[racer2012]

Thanks for all the info ..  I'll get a motor to jump in there to see if that takes care of it before I dig any deeper .. 

Thanks again....

 

[miesk5]

yo Racer,

yw

If you get a new motor;

1356 Electric Shift Motor Replacement
Source: by autopartsdirect2you via Alex M at Ford Bronco Zone Forums

very easy instalation... 3/8 drive socket wrench and 10mm socket needed(drop light may be needed as well as a rubber mallet). there are 4 bolts holding this unit on. one bold holds the back brace on and 3 hold the housing on. there is one plug.

step 1 disconnect plug and swing it out of your way. to disconnect connector from unit depress tab on back and slide downward.

step 2 remove one 10mm bolt from back brace.

step 3 remove 3 bolts from motor housing to transfer case.

step 4 unit can be pretty hard to get off( depending on how long it has been on) so you may need to tap it with a rubber mallet.
Installation

step 1 match the unit female to the transfer case male and slide on.

step 2 line up your bolt holes and start bolts.(you may want to put some thread lock on them to ensure the do not back out)

step 3 tighten all 4 bolts to about 40-50 inch pounds.

step 4 connect the connector back and slide onto the new unit.

now you should be ready to try it out. double check your work and follow your instructions for 4x4 engagement.

====
1356 Electric Shift Motor Connector, Missing Pins, Bronco & Ford; "...Carefully record wire pin positions. Using a suitable tool, release each sensor wire pin. NOTE: Some harnesses may have a center pin as shown in the sample graphic. If there is a center pin, it must also be transferred. Install wire pins in the replacement motor connector in the same position as in the original motor connector until they snap in place. Note that the sensor and harness wire colors must match. Verify pin placement, then replace red locking tab. This completes wire pin transfer. The white pins are the ones for the speed sensor that need to be transferred..."
Source: by CARDONE®
 

You have to remove those three wires from the old t-case motors connector, and put them into the new connector (naturally they have to go in the same places on the new). Just use a dental pick and release the wire from the old connector....then they should just click right into the new connector......like I said just be sure to put them in the same locations as they are in now on the new connector......there are three open holes on the new connector thats where they go..  you will see that those three wires can not be removed from the t-case, but if you use a dental pic like I said you can just slide them out of the old connector and then right into the new one (they will just clip right in when you seat the pin all the way in)......there is a total of ten wires that come from the t-case.....seven from the motor, and three from the t-case it self.......and there are seven existing wires on the new connector you/we have.....just a matter of adding the three from the t-case to make ten........look at it close and you will see exactly what I am talking about.
I would go under the truck with the new motor, and just pull the wire from the old connector and then put it right into the new one to avoid any confusion. Start with the one in the center, then match the other two up using the color of the wire next to it for a guide.....should take less than 15min to do the job

by Streetgang