Yo lil,
Does it have the manual shift or electronic shift on the fly (ESOF) transfer case?
If esof:
1356 Electric Shift Troubleshooting & Repair - BEST PROCESS!
Source: by Dustin S (Dustball, Mellow Yellow, Mr. Laser Boy) at
http://web.archive.org/web/20100923194404/http://ylobronc.users.superford.org/documents/electric1356/elec1356.htm
In this article see more info on performing this motor test;
#1 failure is Transfer Case Motor
To check if the transfer case motor is actually functioning (because it may be hard to hear it in a noisy shop) attach a voltmeter to A4 and A5. Have someone activate a shift and look for a brief (one second) increase in voltage and listen for the relay to click on, then off.
If there is power present, then the control module is trying to run the motor. At this point, unbolt the motor and have someone activate a shift again. If the motor doesn't actually turn, it is malfunctioning and must be replaced.
If there is no power to the motor, check both the power circuits again and the sensors. If there is incorrect sensor data, the module won't power the motor.
If ESOF,1356 Electric Shift Motor Troubleshooting & Repair (travel stops)
Source: by Richard C (Bigric, Money Pit) at
http://www.supermotors.net/clubs/superford/vehicles/registry/4584/21843
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® cardone
1356 Electric Shift Motor Connector, Missing Pins in a 93; "...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..." read more
Source: by Streetgang (Steven F)
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MANUAL SHIFT:
System, Service
FROM 96 Bronco-F-Series Workshop Manual (PARTIAL) by FORD via
http://www.diesel-dave.com/vehic/manual/stj/stjleft.htm
Same as most earlier years especially 92-96, excepts for OBD II in 96, 4WABS (93-96); ABS (87-92); Air Bag (94-96); 3 ***** Automatic Locking Hubs (Built from May 95 through 96); Spark Plug Wire Routing & Firing Order (The firing order for 1987-1993 5.0Ls is 1-5-4-2-6-3-7-8. The firing order for 1994- 96 5.0Ls & all 5.8Ls is 1-3-7-2-6-5-4-8.);
2-piece Spindle Rolling Diaphragm Seal (RDS) used on 5/95 to 96 Broncos & F Series 1/2-ton 4WD
and a few other items that I still need to research
DESCRIPTION AND OPERATION
Windup and Delay — Shifting Out of 4-Wheel Drive
NOTE: To determine if driveline windup is causing delayed shifts to 2WD, jack the vehicle or lift it on a hoist with the wheels free to rotate. This should release the driveline windup, if it is present, and the transfer case (7A195) will complete its shift, if windup is the concern.
NOTE: Vehicles vary in terms of how "tight" they are. Some vehicles have a lot of "give" in the system. Softness in suspension and mounts will allow the driveline to absorb more windup before it affects performance. If driveline windup occurs, the system will tighten like a giant rubber band until the tires start slipping. A "tight" vehicle will signal the windup sooner, usually by a lot of chattering noises.
A delay or a failure to shift out of 4WD may be the result of driveline windup or extremely cold temperatures. In 4WD, windup can develop, especially if the vehicle is operated on hard, dry surfaces or in tight turns. The driver may select 2WD, but the shift doesn't take place even though the 4WD light goes out. Also, as long as the transfer case doesn't shift, the hubs remain locked and the vehicle remains in 4WD. If windup in the transfer case is severe, even backing up may not release it.
In order to return to 2WD under these conditions, two things must happen. First, if the transfer case doesn't shift right away, the vehicle will have to be driven in 4WD until the windup is relieved or until the axle warms up. Second, when it does make the shift, the driver will have to stop the vehicle and go straight in the reverse direction for at least ten feet to unlock the hubs.
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