VTX1800N1

No problem. The system can get confusing sometimes, especially when it does something weird like this.

techrep

iTrader: (1)

agree...

sjwelds

Weird is right. VTX, I'm planning to change the tcase fluid, drive it for 10 minutes or so, change the fluid again, drive it a bit again, and then see if it'll go into 2hi.

If it doesn't shift, I plan to pull the tcase shift motor, see if it turns, and see if I can turn the shaft with a pliers or screwdriver. If both of these are successful, I'll put it all back together and try it electrically again. If the motor doesn't turn I have a new one to try.

If I can't turn the tcase shaft, I suppose that means getting the tcase repaired?

Do you see any flaws in this plan? Any other suggestions or tips?

Thanks again. You've been most helpful.

techrep

iTrader: (1)

The only thing i see is I doubt changing the fluid will do anything...unless it's ready to be changed anyhow..good luck

sjwelds

Well I checked it a few days ago and it was quite thin and dark brown or purple. VTX thought it might have something to do with the electromagnetic clutch inside the tcase not unlocking.

You can read more about this all here: https://www.f150forum.com/f72/how-di...86872/index21/ and back a page as well

sjwelds

Failure.
Pulled the tcase motor. Shaft turns manually, no problem. Put the new motor on, no change. Changed tcase fluid, went for a drive, still in 4hi or 4lo.
Even when I put it in 2 wheel drive manually, the 4x4hi light stays on.
Gave up, loaded it on the trailer, took it to my mechanic.
Seems like it has to be an electrical issue.

VTX1800N1

If you manually moved the TC shift lever into 2WD and the front drive shaft is still locked in, it might be time for a new transfer case. From your description of the condition of the fluid, that might have been the cause....

sjwelds

Well didn't actually jack the truck up and check that. Hopefully that's not the case. Even with the tcase motor unbolted, it didn't switch when turned with the switch on the dash. Makes me think electrical...

sjwelds

Update: Turned out it was the switch. My mechanic did a bunch of tests on it with his scan tool and that's what he found out. Sure am glad it wasn't the tcase. All's well now.

So guys, the switch is not invincible!

Thanks again for those who shared advice with me.

stringer

I am glad you figured this out. I went through this same exact problem on my Ranger and I was going to say it sounds electrical. Instead of it being a faulty switch it ended up being a fried 4X4 control module on my truck.