My problem is while driving my 03 4x4 with electric shift t-case, the case will engage out the blue for no reason. The 4x4 light comes on the dash and even though the selector switch **** is in the 2x4 positon, the 4x4 indicator light position is illuminated at the switch. While stopped, I can sometimes fiddle with the **** and get the indicator light to light back up in the 2x4 position. The problem has gotten progressively worse. It seems there are one of two likely causes, either the selector switch on the dash is fubar or there is a position sensor on the shift motor that is bad? I have no DTC's present even though the "SEVICE 4x4" light did come once but never again. When I shut the engine down and with the tranny in neutral and just turn the ignition switch back on while the problem exists, I can hear the shift motor acting irratically and when I fiddle with the selector switch, it will eventually go back into 2x4. I have had a couple of instances while the engine is running and tranny in neutral that it will not go back into 2x4 no matter what.

So does anyone have any experience with this? I'm lost and don't want to start throwing parts at it without a better diagnoses. This seems like a safety issue to me but I checked and the truck is free of any outstanding recalls. At that point, the local dealers could care less about what I think.

Help!

 

The first thing i would do to prevent damage to your T-case would be to make sure it was in 2X4 then unplug the shift motor that should buy you some time to drive around in it if you have to. then have the truck in park and have some one play with the switch while you check connector from the truck to the shift motor with a multimeter. look for irregular voltage I can’t tell you what the voltage should be exactly because I don’t know off hand but it should be around 12v. also check your grounds make sure they are good and look for any damaged wires. I would eliminate the shift motor because it sounds like it’s working like it should. I could not find a wiring schematic so I can’t tell you how many relays are in between the T-case and the switch it could also be one of them. hope it helps some I will see if I can find more on but that’s all I have for now.

In my experience with electrical stuff it's usually something simple just finding it is a pain in the a** then you feel dumb for not finding it right away

 

hey check this link they have a lot of stuff just two much for me to look at http://www.2carpros.com/forum/1-vf18...days=0&start=0

 

I had a problem somewhat similar on an electonic shift transfer case in a Bronco, and it was a bad ground on the control module. Don't know off the top of my head where or if this specific component is on your truck, but like mentioned earlier, it's probably something simple. Just a pain in the #$% to find.

Good Luck!

 

Thanks for the responses guys. I pulled the connectors off position sensor and actuator motor, sprayed contact cleaner on them, used a pick to respring the contacts, added dialectric grease and re-installed them. I have driven about 100 miles since I did this and the problem has not returned. It appears as though I had a continuity issue with position sensor connector that caused the odd behavior of the actuator motor.