OT: Ford 4X4 Auto Problems.

Ric Ks.

Member
Sorry for the OT but this thing is driving me nuts.
2002 Ford Explorer wont stay out of 4X4.
It has 3 selections Auto, 4 High, 4 Low.
I put 4 brand new matching tires on it.
To get it to release I hold down the auto button and back in a circle. It wil crab a couple times then pop out.
Most times it will stay out until I turn it off. Then its back in 4 again next time I start it.
The indicator doesnt always show 4X4 but you can feel it straining and crabing on corners.
Used to be a cold weather problem but its gotten worse till it is a constant problem now.
This is an early 2002, I have a late 2002 so the mechanic thought he would swap the controller module-- nope the fuse blew that locks the steering???
That also scares me. THERE IS A FUSE THAT IF IT BLOWS THE STEERING LOCKS!!!!! What happens if Im going around a curve at 70MPH and the fuse blows???
Anyway Im hopeing some Ford Engineer or Mechanic might see this and have an Idea.
I wonder if I remove the speed sensers from the driveshafts and isolate them so they think its standing still all the time would it kick in??
Can it be made to have a manual on off only?
 
My experience with electronic 4X4 is the transfer case position sensor goes bad. That is what tells the rest of the system what gear the transfer case is in. I've had to change them in a Ranger and the Z71 that I have now. The Ranger wouldn't shift into 4X4 and the Z71 would shift all by itself. Sometimes when I started it it would be in low range other times it would be in 4-wheel drive, but the indicator lights would all be out. For what it's worth on the Z71 I was able to drive it in Auto until I got the parts to fix it. For whatever reason that seemed to make it happier.


I wish they would make the newer light duty trucks with manual 4X4 and manual transmissions, but apparently I am in the minority.
 
fuse will cause it not to come out of park so steering will be locked but once out of park steering will not lock as long as not put back into park. will not lock up driving unless you put in park while driving. (not good idea) you have auto four wheel drive, it runs in 4 wheel continously, but has adifferential effect when not in lock positon. sounds like a drive chain loose internaly.
 
Since it switches back to 4WD when you shut off the engine, I would suspect you have a vacuum switch that's faulty. In my '06 F-150 there's a vacuum switch on the upper part of the firewall that gets wet whenever rain runs off the windshield, and the electrical contacts corrode and the truck switches to 4WD. The new version of that switch has a rain shield that fixes the problem. Earlier Explorers had the transfer case motor problem that the other poster mentioned, (my '90 Ranger has the same problem) but that wouldn't cause the truck to switch back to 4WD when you turn it off.
 
"Earlier Explorers had the transfer case motor problem that the other poster mentioned, (my '90 Ranger has the same problem)"

Yep my Ranger with the transfer case shift motor issue was a '92. I put Warn manual locking hubs on it to because the auto hubs quit working. Then I got a '00 Ranger 4X4. The transfer case shifter always worked on it, but again the hubs wouldn't always lock themselves in. So I put an aftermarket set of locking hubs on it too. Decided I had had enough of the Ford 4x4 problems and got the Chevy Z71 only to have to replace the sensor in the transfer case shift motor less that a year after I got it. I guess that I also have to keep in mind that it is the "newest" vehicle that I've ever bought and was 3 years old with about 85K miles. The '92 Ranger had well over 250K miles on it when I finally let someone else have their turn with it.
 
My '90 Ranger was a weird combination of that gawdawful electric shift transfer case and manual hubs. Never understood why they got rid of the nice manual transfer case that they had in '88.
 
if it has auto/4high/4low it runs in 4wheel full time. the transfer case acts as a traction lock rear end, the axles can run different speeds in 4auto, when 4high or 4low is engaged it keeps the front and rear together like a positrac. there is no shift motor. it will never run in 2wheel drive. can have chatter in viscous clutch, my experiance is chain gets stretched with miles and starts slipping.
 
sorry my bad that year did offer both auto and all wheel drive. yours may have the shift motor and usualy that is the culprit.
 
I'll have to think about this one a while. There is no fuse that can blow and lock the steering. The only way to lock the steering is turning the ignition lock to the "Lock" position. If the shift lever is not in "Park", you can't lock the wheel.
 
Thanks Guys for the input. I was leaning toward the shift motor as the problem and will go there next. I know its a constant 4 wheel but when the transfer case drifts from auto into 4high it eats the tires and im sure wares all the components.
 

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