2003 ford excursion 4x4 not working

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4x4 Not working (no light)

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So I have a 2003 F350 6.0 and when you shift it into 4wd hi or low nothing happens. No lights on the dash come on and I have tested and there is no power going to the motor on the t-case. Any ideas? I have tested all the fuses I could find and have switched out relays under the hood to check that, but still nada. PLEASE HELP the snow is about to fly  

I am having the same problem. i've been searching post but not finding this same situation. Mostly hub problems.  

quick fix i took off the motor that on tranfer case and put on a 9/16 wrench and turned it to back of truck ..to engage 4x4 to hi at least if you get stuck you can get out ..  

Did you find the problem yet?  

I replaced the motor on the transfer case but still nothing. I can hear the relays clicking under the hood when I turn the switch but its not engageing. No light on the dash or the switch. Also no sign of vacume leak. a/c stays the same when I turn 4wd on.  

So, there is now power at the TC switch motor? My next question is did you manually turn the engagement shaft when you had the motor off to see if it would engage easily, before putting the new one on? I can't remember the exact motor logic anymore, but it tries for about 20 seconds to engage before it cycles itself off. Unfortunately, the ESOF can be a PITA when things stiffen up in the TC. It is always a good idea to cycle it and run it in 4x4 on a regular basis, just not on a hard surface. The light comes on when the motor has rotated the shaft to the correct position.  

I did not try to turn the shaft. I take it that it will get bound up internally if not used often. I bought the truck 8 yrs old with 20,000 miles on . its got 27,000 now. I was hoping it would'nt be anything internal with that low milage. Will moving it manualy get it to loosen up or do i have to move it then drive it and then move it back? Also only one pin had power to the motor . I did'nt know if they both should or not. Thanks for help. Im kinda stuck.  

Also have the same problem, mine is an 03 also, out of curiosity does your 4x4 switch light up with your parking lights on, mine are out, wondering if we have the same symptoms, maybe we can both figure this out, im very frustrated.  

No the switch does not light up at all. The 4X4 and LOW RANGE in the instrument cluster only light up when I start the engine and then go out like all the others. Nothing lights up when I turn the 4x4 switch.  

motorman173 said: No the switch does not light up at all. The 4X4 and LOW RANGE in the instrument cluster only light up when I start the engine and then go out like all the others. Nothing lights up when I turn the 4x4 switch. Click to expand...

the 4x4 and dash light are tied to the PCM the system has no clue what so ever if the hubs did anything but the transfer case motor has some hall effect sensors and can tell if the motor moved to the expected position and then will turn the dash light on accordingly  

I do have power to one of the two pins at the motor when the switch is turned but its only one. I was afraid that it is the GEM also. I just read about that. Someone said you can by pass it but there were no details as to how. Twoicebergs asked about turning the shaft. I will be trying that in the morning. This is my first truck with this electronic crap 4x4. So far it seems better for the parts suppliers than the truck owner. IMHO  

motorman173 said: I do have power to one of the two pins at the motor when the switch is turned but its only one. I was afraid that it is the GEM also. I just read about that. Someone said you can by pass it but there were no details as to how. Twoicebergs asked about turning the shaft. I will be trying that in the morning. This is my first truck with this electronic crap 4x4. So far it seems better for the parts suppliers than the truck owner. IMHO Click to expand...

No. Sorry. I just heard about it myself searching the forum. How hard should it be to turn the shaft with a wrench and which direction does it turn? clockwise or counter clockwise? The GEM is said to be behind the glove box.  

I think from the 2wd position you can turn it clockwise or counter, could be wrong it should turn easily. Also i am usure if there is a neutral position.  

What is a GEM? Not hijacking but my Dads 03 is doing the exact same thing, turn switch and no lights or engagement. Subscribed.........  

I guess its a controler of some sort for the 4x4 system. I guess the old tried and true method of grabbing a lever to enguage the 4 whell drive was too simple.  

I agree wish i had the sure stick in my truck. Of course mine fails in the biggest snow storm we have had in years. Im leaning towards my GEM module but its kinda pricey to just throw one at it. Anyways these can be tested with a scantool or something? Any ford techs that would know? I think you can pull codes from this module.  

I would love to figure this out all the threads i have read on here seem to lead to dead ends. I did see one where a guy had a broken wire underneath the relays under the hood, i am going to inspect this area on my truck and go from there  

u can pull codes with a good reader the GEM doesn't just usually fail one item and I am not sure the 4X4 runs through the gem anyway ? I do know it is a PCM /ECM 's job to send the signals out to the TC shift motor and ESOF solenoid the chances are greater the Transfer case motor or wiring have failed specially if u hear relays clicking ,, but it could be the relay as well I have all the manuals but have not had to dig into this system yet  

Yeah. I couldn't find anything that really helped with this problem very much. Might not have used the right search words. I do understand how to troubleshoot the vacume hubs. Another brilliant idea. Lol  

well a manual transfer case was an option and it came with manual hubs u can even convert yours but I like the ESOF I just check it every once in a while  

I replaced my motor a year or so ago and i definitely have no power going to it. The GEM module is split into 2 categories for this year for 4x2 and 4x4 model trucks so it has to have something to do with it i would imagine.  

I have same issue but have no relay click. Tried swapping them and no results Sent from my SCH-I510 using AutoGuide App  

Ok. I took the motor off and put it into 4 wheel manualy. For future refrence the shaft turns counter clockwise to engage. I did this about a dozen times to loosen it up then drove it around for a couple of miles to get the internals moving. When i came back I put it all back together. When I turned the switch I can hear the relay Going on and off but it wont engage the transfer case. I've had it with this thing. Its going to the shop.:dunno:  

Just out of curiosity, did you try the motor off the shaft? As well, how much force did you need to turn the shaft? The TC shift motor doesn't create much torque. Keep us posted on your shop repair. BTW, one of my previous low-use trucks developed a similar problem. After 9 years of living in the rust belt everything started to get stiff. The shaft was easy to move when warm, but when it was <0*F it did not like to rotate/shift. It finally burned out the TC shift motor and I replaced it - that was when I really found out what the problem was. Rather than take off the TC and repair/replace the sticking parts, I used some penetrating oil on the shaft support and seal. When parking it in the winter I used to put it in 4x4, just in case I needed it on the next drive. Call me lazy, but it also exercised the parts. I ran it like that for a few years; it got better, but never back to normal. Since this happened, I always engage 4x4 every day I drove it. Same for my new truck, and after 110,000 miles, even at -26 its shift into 4x4 like new.  

I did not try the motor off the shaft because the instructions said not to and that it would void the waranty. The shaft was kind of stiff but without any type of refrence I cant tell if it is normal resistance or from lack of use. Do you know if it will hurt the motor trying it off the T/C? I did spray PB blaster in the shaft while it was apart.  

Anyone have any word on this problem yet? I'm having similar issues but mine has a mind of it's own. Sometimes it works fine, sometimes it don't. It also will work till I shut truck off then it won't work and be stuck in 4wd. Or vice versa. Replaced switch cause it didn't light up with parking lights. Now it lights with parking lights but still has mind of it's own to when it wants to work.  

The answer I got today was that they had replaced both relays under the hood. I could hear it clicking trying to turn the motor but apperantly they were still bad. They cost about $30 each. I would start there if the wiring looks good. Its probably the cheapest place to start. The motor was $120.I was also told that the relays for the 4 wheel drive are the same as the relays for the wipers and horn under the dash so you can swap them in to see if that is the problem. I hope this helps.  

Check this out..... http://www.powerstroke.org/forum/showthread.php?t=284350 Sent from my phone that somebody didn't help me get.  

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4 Wheel Drive Not Working - Relays?

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My '99 has Warn hubs, but this problem is not at the hubs. My 4-wheel-drive is not working. When I move the switch into 4WD-Hi I get no 4-wheel dirve and no indicator dash light either. I bought the truck used years ago and it never did have Low Range 4-WD. If you flipped the switch to low range it just lit up the dash light and was in high range. Then at the end of last winter on day I flipped the switch and got no dash light at all - its been like that ever since. Yesterday I crawled under the truck while my wife moved the switch across the various positons. There was no noise of it being acculated at all. After doing a Search and reading dozens of threads I've noticed several references to Hi and Lo range relays for the 4WD. Can anyone tell me if my symptoms point at bad relays (sudden loss, no apparent mechanical problems, no dash light, hubs not involved) and if so just where are these relays located? Any help appreciated. Oh, and if this thing shows me to be a first time poster its incorrect. I just had to re-register because I forgot my password and we have changed E-Mail address.  

The electric shift t-case is controlled by the GEM on your truck, using feedback from a position switch on the t-case shift motor. The motor gets power thru the relays, but your prior problem of getting into 4H but not 4L points away from that being the problem, at least initially. The relays are actually "shift to 2WD" and "shift to 4H & 4L". They just control the direction that the shift motor turns. The position switch controls where it stops turning. I'd check under the truck for wires that may have gotten hit by a rock and broken, or corroded connections at the t-case motor plug. It's also possible that the position feedback switch has gone bad.  

my 01 had the same issue, turned out to be a corroded connection under the relay box under the hood.  

Thank you folks. I have crawled under the truck looking for disconnected wires and such but everything looks good. Under the hood I have another problem - I have no idea where the relays are located. The large under-hood fuse box (next to the brake master cylinder) is where the Owner's Manual shows them to be located - numbers 39 and 40 according to my book - but the actual fuse box only has 38 holes. There are no spots for relays number 39 and 40. However next to the main fuse/breaker box there is a second box that holds two rather large breakers (about 3/4" square). I am assuming that these are the Hi and Lo relays. Is that correct?  

That second box is for the towing accesories I believe.  

ESOF shift relays are located in a box in front of the main fuse box. Identical to the one between the main fuse box and master cylinder that's for trailer tow stuff.  

2001 excursion 4 wheel shift relay location No 4 wheel high or low lights inop, test lights work on start, where are the two relays located 2001 excursion 7.3 automatic. Hope you can help? LEE! I took another look and there are four relays mounted on the passenger side of the fuse box under the hood. They are mounted in two separate holders two to each holder one closer to the firewall and the other toward the front of the eng. All four relays contacts look great. Will the motor encoder cause no shift to high or low with no light indication on inst. panel except for ckt. test on start which is working as advertised. Also no click heard when selecting high or low all fuses are good.  

ESOF relays are in the same place (in front of the fuse box) on both the Excursions and pickups.  

no 4x4 Thanks for the info, finally found the right two relays one was flaky but still worked, changed it anyway finally replaced shiftmotor on transfer case to the tune of 558.00 and works as advertised now. looking at the schematic finally figured out the two relays I needed have all five contacts in the plug end and the other two relays which are the same part number are only using four contacts in the plug they are into. thanks for the help LEE!  

Both ESOF relays need to be good for the system to work. Power goes thru them both to complete the circuit. When the system is not calling for the motor to run, both relays are de-energized and connect both of the motor leads to ground.  

i replaced both relays, on a 2000 there r 2 little covers.. each have the same 2 relays.. i changed all 4 just for fun.. cheap 15 each.. no 4x4.. checked vacum system by switching to 4x4 and air comes out of dash vents.. so no vacum leak. put them in locked mode.. still no lite.. so next i reckon to change the motor. it is easy to change. but i have 2ft of snow out front.. Ford service said rock the truck. back and forth. that did not work either. spun wheels in snow. lite on end of shifter came on.. got rear too hot. now have to change fuild.. this 2ft of snow is not fun. next fall i will tune up 4x4. not wait for blizzard  

2' of snow in St Augustine? How long were you spinning your rear wheels to get the OD light to come on the end of gear shift? Was the OD light flashing on & off? I am trying to find that recent thread for you of the guy who just switched his ESOF to Manual Floor shift but still no luck.  

Does anyone know of a way to change the electronic system to a manual one? Vacuum plugged, warn hubs done. I was just wondering if anyone actually figured out a way to make the ESOF a manual system? -Eric  

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4x4 not working no lights

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ok 4x4 was working fine to other day. now when i start the lights come up as normal and then goes off. when i flip the switch to any pos(4x2-4x4) no lights and the transfer case doesnt engage. is there a way to test the motor. i have turned truck on there is no power on any of the wires to the switch or the transfer case motor. do any of the wires has power running to them or is there a way to check the switch? also my fuse 30a in the power distrubution box appears good, any other fuse controling the motor?  

no power to the switch means the problem is before it. looks can be decieving. replace the 30a and see if it works then.  

ok had my brother test the fuses, the relays and everything appears good. it has power to the relays that are on the side of the power dist box. but with it running there is no power to the switch, trans case motor. is there something i am overlooking or how do you know if the gem is bad?  

ESOF testing should be easy to find online I have a few test PDF's  

There are 2 relays under the hood in front of the master cylinder that are the 4hi to 4low, 4low to 4hi switches. $30. Just did it on my 02.  

I am having the same problem in my 03. The relays wouldn't make any sense in my mind because he has no voltage in the switch itself. After turning the switch it would power the relays and go from there right? He asked the question I have been wondering about for months, Should there be constant voltage at the 4x4 switch on the dash if you were to measure the plug on the bck of it while the truck is running? Also I have heard that the 4x4 should engage when working properly with the key on but the engine off as well meaning that there should be voltage present at the input of the 4x4 switch with the koeo. Is this correct? I have never gotten to try it while it was working lol. This problem is driving me crazy! I have not had time yet to pull the dash to get to the back of that switch (is there a easier way to get to it?) to test voltage to my switch but, I also have no lights on the dash when 4x4 switch is engaged and no voltage to xfer case motor. I have pulled all associated fuses in the kick panel and tested them for continuity with a multimeter and they are all good. There was about 6-8 of them all together that I found the fuze numbers from a different thread. Anyone have any ideas?  

I had the same exact problem. Turned out to be a burnt wire that was going into the gem module. So before replacing the gem check the wires. I had a shop do mine so don't know the exact wire they replaced, but they went to replace the gem and before they plugged the new one in they noticed the wire.  

ya mine worked fine, then stopped. replaced the gem and worked fine for a few days, then i reinstalled my chip and it seems like after that it stopped working again. i installed it and needed to remove more glue on the terminal so the first attempt it didnt start. once i reinstalled it everything worked fine until i noticed the 4x4 not working again. would a chip cuase the 4x4 system to mess up? hate to bite the bullet but may have to take it somewhere wed to get it looked at.  

Don't laugh.... check your battery cables. My 4x4 would work one day then not work again for a month, then work once again for a day and then nothing for 1 to 2 months again. I tried TC motor and a dash switch. Then one day my truck was dead and when I hooked up the cables to my passenger battery, the positive lead was loose enough to remove by fingers. I had never touched that battery before. I tightened it and now my 4x4 has worked every time for the last 2 months. Coincident??? I think not.  

Also when i tested the switch there was no power to it at all. Same thing for the TC motor.  

ok i might have to try that.  

My 08 350 is doing the same thing and also just noticed the tow setting will not engage. I changed the fuses and relays under the hood with no luck anything else I can try before the shop?  

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4x4 not working, 2006 expedition eddie bauer - seems to be different than most issues

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Hello, first of all thanks in advance, and for the add to the community. The four wheel drive is not working properly. When I put it in 4auto, the dash notification center (DNC) lights up and says 4auto is engaged. Which of course is great and normal. When I put it into 4H, there is no notification, and nothing happens, no click of the TC even when driving foward slowly. When I go to put it into 4L, again no notification, other than it telling me to put it into neutral and to apply the brake. Which, of course I do, but if I put it I to reverse or drive, or take my foot off the brake it just tells me again to do so. Again, no noise even when rocking the car back and forth. I've checked the manual and very carefully followed the procedure to shift, along with checking the fuses but nada. If you have any clue as to what is wrong, I would appreciate it! Thanks  

Bump  

Hey thanks for all the responses! Anyway. I figured it out. The transmission was replaced a year or so ago (Ford quality right?!) And the tech didn't snap one of the transfer case plugs all the way in, and it must have vibrated apart. Long story short, take a bit and once over all of the electrical connections before you start replacing parts. Cheers  

You do realize that we are all volunteers who don't get paid for this, right? Sometimes we don't get to things within the first few hours. Although, we are glad you figured it out.. It may help someone else down the line.  

Apologies for not being on call 24/7 to answer your questions and subsequent " bumps " .......................Nah , I'm not really when I see your reply . Good you got it fixed . " Long story short " ............." Seek and you shall find "  

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2003 Navigator 4wd not working??

• Thread starter 96mustangV6
• Start date Nov 7, 2013

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• Nov 7, 2013

96mustangV6

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I just bought a 2003 Navigator. It has the 2h, a4wd, 4h, & 4lo switch. If I switch it to a4wd it doesn't do anything. When I go to 4hi or 4lo I can hear a relay click but no lights on dash come on and I don't feel anything like it engages. ( my 98 you could feel it engage) when I turn key in truck the 4hi and 4lo bulbs light up so I know they arnt burnt out. But I don't see a a4wd light on dash. Am I doin something wrong. I tried in neutral and park. I pulled forward and reverse while it was turned to 4wd and nothing. What are some things I can check. Thank You  

ExpeditionAndy

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IWE relay?  

check fuses F1.115 F1.20 F1.11  

What's that. I literally just picked this Navigator up last night. So I'm not familiar with it. So far only problems I found are no 4wd and no cruise. Which he said he replaced brake booster so I'm goin to make sure everything got plugged in. But I'm just trying to find out why I hear a relay with the turn of the 4wd switch but nothing happens. No lights on dash light up.  

shift control circuit  

• Nov 8, 2013

I'll look but I don't see why they would. It has the 2h selector so its not full time awd.  

FordCustSrvc

96mustangV6 said: I just bought a 2003 Navigator. It has the 2h, a4wd, 4h, & 4lo switch. If I switch it to a4wd it doesn't do anything. When I go to 4hi or 4lo I can hear a relay click but no lights on dash come on and I don't feel anything like it engages. ( my 98 you could feel it engage) when I turn key in truck the 4hi and 4lo bulbs light up so I know they arnt burnt out. But I don't see a a4wd light on dash. Am I doin something wrong. I tried in neutral and park. I pulled forward and reverse while it was turned to 4wd and nothing. What are some things I can check. Thank You Click to expand...

when I checked the wiring diagrams for both the 4wd and cruise I notice that the ABS Control Module is common to both circuits. Not saying that is your problem but its possible it could affect both the 4wd and the cruise  

96mustangV6 said: I'll look but I don't see why they would. It has the 2h selector so its not full time awd. Click to expand...

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