93 Explorer 4WD doesn't work

All of a sudden the 4WD stopped working. I checked the switch unit in the dash and it was bad. Replaced the switch. Checked all fuses. When I push 4WD High or Low button I hear a relay click in back of vehicle. Amber lights next to switch buttons don't come on. 4WD does not engage, or doesn't stay engaged. Front drive shaft does not turn at all. Is this an electrical problem? Engaging motor in the transfer case? Is there a vacuum line that keeps it engaged? How do I check to see if the auto-hubs are working?
Please, any ideas anyone has would be appreciated. It's about to start snowing!
Thanks.

Hi,
I have a 94 explorer that did the same thing last year (91-94 use the same system). The problem is a broken "stop" on the electrical switch that engages the transfer case. To replace it unbolt the switch from the rear on the transfer case. First you will need to pull the wiring harness out. One of the wire won't come out so, pull the "plug" (that the best way to describe it) out of the middle of the harness. Then remove the wire. Now the entire motor/switch assembly should come off. You will probably find a few small "chunks" in there. They are what is left of the stop (i.e. your problem). To replace it go to a hardware store and pick up a foot of hard plastic tubing that fits over the stop on the gear. Take the gear with you to make sure it fits. Clean the brushes and contacts on the motor with an electrical cleaning spray and a rag. Put it all back together and it should work for ya.

I am going to try and email you a couple of picture that I had found when I had the problem. If you don't get them, send me an email at brianposs@hotmail.com

I have been recieving tons of emails for pictures, so I talked to a friend nicely and he is hosting the pictures on some web space of his. Explorer Transfer Case Pictures (http://www.chevihemi.com/school/explorer/Explorer.htm)

You don't recieve emails. So send me one with your return address

That was my exact problem. Thanks for the help and the pictures. Saved me a lot of money. This is a great forum!

Ok I did everything you said above and the 4WD works fine and I have used it a couple times when today I just thought I would try 4x4 Low and it does not engage. But 4x4 High works fine so I guess I can live with that. (At least until it gets warmer out to work on it) If you have any ideas why one would work and not the other, please let me know.
Thanks.

Are you in neutral when you try and shift into 4X4 low? The explorer will only shift into low when in neutral, park doesn't work. If it still isn't working check to see if you put the wires back in all the way. Otherwise look at the switch itself. If it is switching into 4X4 high I don't know exactly why low wouldn't be working.

Hey frank I am having a similair problem, could you please send me those pictures as well. Thnx

fIXED MINE TOO THANKS

My 4wd doesnt engage anymore either... sounds like the same problem. Can someone email the pictures of this solution to me? Thanks in advance.

what about if you can't get it OUT of 4WD?

I think I have the same problem with mine,my light dosen't come on.
A picture or a link to it would be great!
Thank's
stripers41@bellsouth.net

Can you send me the pics please..

Thanks
V

I am in desperate need of the diagram.... hildemaroyepez150@hotmail.com

Hi My name is Chris, and I have a 91 explorer, same problem. Could I trouble you for those pix too?

Thanks, C.
crooty@yahoo.com

I have a slightly different problem with my 94 Explorer. When I press the 4x4 button on the dash it comes right on and I can hear the shift motor working. It makes you think its on but infact the front wheels don't engage. Anybody have any ideas?
Thanks

mechanicman11375@yahoo.com

Please send pics ..

I have a slightly different problem with my 94 Explorer. When I press the 4x4 button on the dash it comes right on and I can hear the shift motor working. It makes you think its on but infact the front wheels don't engage. Anybody have any ideas?
Thanks

I think you spun out your wheel lockouts. If you have ever shifted into 4X4 "on the go" I guarantee this is what happened. Always stop when shifting into 4X4. I know Ford says you can, but the reality is that you can't do this. To check if they are spun out, take one of your wheels off and look at the hub (the thing that falls out the the center of the wheel when you take it off) if the splines are "rounded off" then this is your problem.

Well actually I have to ad more crap to this story. I do have an extended warranty that I just purchase. But it takes affect in 30 days.(2002 xls 4.0 4x4)And even then I have to wait a bit before I take truck in for any issues, or coverage may be voided if the warranty is bought while truck has issues. Anyway. .. my truck keeps getting locked into 4x4 mode. I have to get out disconnet the battery and then I am able to drive. At this time my 4x4 high and low can be activated ...While driving in auto....the truck will at some point go into 4x4 and I wont know. I only find out when I go to turn and my front end screams for hell with noise and chatter. When I go to test my 4x4 high or low buttons they no longer work. I then have to do the whole battery thing again. I ended up pulling my #12 fuse for the module....sucks...now I can't even get the truck to park in a slight snow bank...( i did see me that left wheel spin freely this time..while not in any 4x4 mode) I am still learning about this truck ..so any more help is greatly appreciated...thanks

pics please kramerb12@netzero.net

I have the same issue. It got me stuck pulling my boat out of the lake.

hey guys that got the light comming on but doesnt kick the thing in to 4 wd any ideas?

hello i have a 1994 explorer i have changed my transfer case motor
today with a brand new one form napa
i can not get the explorer to go in to four wheel drive
i have checked the fuse box i am getting power
the controll box in the back just makes a click
no four wheel drive

can any one help

there is a messge in here that helped me to get it going having to do with putting the hose on the stop in the trans motor while doing my wifes i found that on the top of that motor there is an ajustment theres 3 screws and lines bout 6 of them losen them screws and turn the top a bit if you get the contacts inside to line up it will kick in it has worked on both my explorers my email is crashedu182@yahoo.com

Hi,
I have a 94 explorer that did the same thing last year (91-94 use the same system). The problem is a broken "stop" on the electrical switch that engages the transfer case. To replace it unbolt the switch from the rear on the transfer case. First you will need to pull the wiring harness out. One of the wire won't come out so, pull the "plug" (that the best way to describe it) out of the middle of the harness. Then remove the wire. Now the entire motor/switch assembly should come off. You will probably find a few small "chunks" in there. They are what is left of the stop (i.e. your problem). To replace it go to a hardware store and pick up a foot of hard plastic tubing that fits over the stop on the gear. Take the gear with you to make sure it fits. Clean the brushes and contacts on the motor with an electrical cleaning spray and a rag. Put it all back together and it should work for ya.

I am going to try and email you a couple of picture that I had found when I had the problem. If you don't get them, send me an email at brianposs@hotmail.com

I have been recieving tons of emails for pictures, so I talked to a friend nicely and he is hosting the pictures on some web space of his. Explorer Transfer Case Pictures (http://www.chevihemi.com/school/explorer/Explorer.htm)


Hi guys new to the forum.

do you think this could be the same on my 2002 ltd? Mine wont go into 4x4 either.