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Explorer & Ranger Transmissions, Transfer Cases, & Differentials 4X4 Shift Motor Rebuild Password Home Register Members Rides My Posts Top Posters FAQ Members Notices 1 de 31 3/11/2008 16:47 4X4 Shift Motor Rebuild - Ford Explorer Ranger Enthusiasts Serious Explorations http://www.explorerforum.com/forums/showthread.php?t=123542 Register at ExplorerForum.com and gain access to over 1.5 million posts filled with valuable information for the Ford Explorer and Ranger based vehicle enthusiast. Our forums, run by enthusiasts, for enthusiasts, Miniature Piezo Driver covers the Ford Explorer, Explorer Sport Sub Miniature Driver + Controller for Piezo Motors. Trac, Ranger, Mercury Mountaineer, Mazda www.allmotion.com Navajo, Bronco II and even the Aerostar. 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Ford 8.8", Dana 35 Page 1 of 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 > Thread Tools 12-20-2004, 11:44 AM # 1 Brain 4X4 Shift Motor Rebuild Elite Explorer Golden, CO This is a general how-to thread for fixing the transfer case shift motor for the 4X4 models. Many posts on this '92 4X EB and '91 4X XLT site have been great sources of information, but pictures are worth thousands of words. I wanted to put something up for people to point others to when they have 4X4 problems. So here am going to list some key 2 de 31 3/11/2008 16:47 4X4 Shift Motor Rebuild - Ford Explorer Ranger Enthusiasts Serious Explorations http://www.explorerforum.com/forums/showthread.php?t=123542 Join Date: Jun 2004 words to help the searchers: Posts: 915 Transfer Case Electric Shift Motor 4X4 4x4 4WD 4wd 4X Borg Warner 13-54 BW1354 BW13-54 First thing is where is that 4X4 shift motor ? You have to crawl underneath and look at the back of the transfer case (which is behind the transmission). Looking at it from behind it will look something like this: It has been said that tapping or hitting the shift motor will sometimes get it to engage if it is stuck in a position. This may work (it's probably worth a try), but don'tt hit it too hard or you might be looking at $300 to get a replacement. To straight out replace the motor with an OEM or aftermarket one, eight bolts are all that is needed to remove 3 de 31 3/11/2008 16:47 4X4 Shift Motor Rebuild - Ford Explorer Ranger Enthusiasts Serious Explorations http://www.explorerforum.com/forums/showthread.php?t=123542 the motor. Four bolts hold on the weight that is used as a vibration dampener (not shown, but locations are marked in blue), and four bolts hold on the shift motor (locations marked in red are 10mm). Two of these bolts attach a bracket that secures the electrical connector as well as holding a sensor in place (it has an o-ring and just needs to be kept from popping out of the case). There is silicone sealant used between the shift motor and the t-case body, so a little gentle prying might be in order (and don'tt forget to seal it back up and make it weatherproof when you are replacing it). For those of us who don't have $300 just sitting around doing nothing, you might be tempted to fix the motor yourself. Well good for you! I hate seeing good parts end up in the trash because of a stupid little plastic piece (which is one of the main culprits of these failures as will be shown in a bit). To see how these things work I'm going to start at the end and work towards the beginning, which might sound counter-intuitive, but explaining 4 de 31 3/11/2008 16:47 4X4 Shift Motor Rebuild - Ford Explorer Ranger Enthusiasts Serious Explorations http://www.explorerforum.com/forums/showthread.php?t=123542 the "how" requires the understanding of the "why" Showing the build-up seems to show why better than a tear-down. If you want to see a tear-down just read from bottom to top ; ) That being said, let me say up front MAKE A MATCHMARK BETWEEN THE GEAR HOUSING AND THE HOUSING COVER SO YOU CAN GET IT REALIGNED PROPERLY!! I'll say this again later in the post, but some people like to dive into something without reading the entire post, and it will keep you from spending hours of frustrating button pushing trying to get all the positions to work again. A sharpie works well if you rub a small area clean. Here is a picture of the transfer case without the shift motor in place and a close-up shot. Notice the marked positions on the transfer case (2H, 4H, 4L) that the selector shaft points towards with the tip. That order is the order of selection as well. In these shots it is pointing towards 2H (2 wheel drive high gear). If worse comes to worse and you are in a tight spot, you can turn this selector with pliers as you can feel the stops (it sets into place with a springy clunk). 5 de 31 3/11/2008 16:47 4X4 Shift Motor Rebuild - Ford Explorer Ranger Enthusiasts Serious Explorations http://www.explorerforum.com/forums/showthread.php?t=123542 6 de 31 3/11/2008 16:47 4X4 Shift Motor Rebuild - Ford Explorer Ranger Enthusiasts Serious Explorations http://www.explorerforum.com/forums/showthread.php?t=123542 It takes a bit of torque to move this selector from one position to the next so Ford had two options: put a huge honking high-torque motor on it or put a smaller low-torque motor on it with geared reduction to get the torque necessary. The second option is best because it weighs less, requires less power to run it, and costs less. This particular geared combination is called a worm-gear drive. There is a large gear that goes on the end of the selector shaft (shown here on the shaft without the gear housing). The teeth are on the edges of the gear and are angled. Notice on the end of the gear there is a pattern. This serves to allow the computer to sense the position of the gear and therefore the selector shaft. 7 de 31 3/11/2008 16:47 4X4 Shift Motor Rebuild - Ford Explorer Ranger Enthusiasts Serious Explorations http://www.explorerforum.com/forums/showthread.php?t=123542 There are six finger-like contacts on the cover that are stationary, and by a series of open/closed circuits, the computer can tell where the selector shaft is pointing. This is pretty important because of the computer has to tell the motor when to start and stop. If the computer doesn‘t know what position it is in, it will default to a fail-safe mode of doing nothing except blinking the lights to let you know it is confused and lost. The six contacts might be a little corroded (mine were), so I took a piece of super-fine sandpaper (600 grit) and cleaned off the corrosion on the ends where they ride against the large gear. I also gave them a slight bend up so that they would have even more spring force pushing them against the gear. 8 de 31 3/11/2008 16:47 4X4 Shift Motor Rebuild - Ford Explorer Ranger Enthusiasts Serious Explorations http://www.explorerforum.com/forums/showthread.php?t=123542 The gear housing serves in a couple of different functions. It is part of the electric motor (contains the brushes and sleeve bearings), it holds the two meshed gears together, and it has a reœstopto keep the large gear from rotating too far in either direction. The next picture shows this housing and the beginning/end stop wedge. 9 de 31 3/11/2008 16:47 4X4 Shift Motor Rebuild - Ford Explorer Ranger Enthusiasts Serious Explorations http://www.explorerforum.com/forums/showthread.php?t=123542 The back of the large gear has a stud with a plastic bushing (cushion) over it that hits the stop.