Ford 4x4 2002 explorer will not go into 4 wheel drive

[jackwmssr]

I think I need the help of a Ford mechanic. My 2002 ford explorer 4.0 v6 automatic will not shift into any 4x4 positions. I have checked all the fuses that I can find, 1 under the dash and 2 under the hood. It does not make any sounds at all when I push the 4x4 buttons. It did not make any strange sounds the last I used it a few weeks ago. I have tried it moving and sitting still, in neutral with the brake on. I have had it since new and used it every winter so I am sure it is not operator error. It has 99000 miles on it. Now for a little recent history. I had the cables disconnected to clean the post 3 weeks ago. Two days later I used a homeowner style alternator tester to check the alternator (good). I jumped the MH last week to start it, all of these since the last time used the 4x4. While doing the above I never did hook any thing up wrong. THE FORECAST IS CALLING FOR SNOW tonight 7 to 9 inches. I would be very thankful if some one can help me with this.

[j-d]

You're limiting your search for help by asking on an RV forum. I like BAT Auto for Auto/Truck issues, even RV stuff that's strictly chassis. There are way more guys working on 4x4 Explorers out there than you'll find here.

[jackwmssr]

I unhooked the battery cables and left them off for a while as I had heard might reset something but it did not help. After that and removing and testing the fuses and reinstalling them I now have a 4x4low light and a door ajar light that are on faintly all the time. Still no 4x4 action though. I will try the soft blows to the servo motor when the weather is a little better. Thanks for the ideas. The snow is over, 10 inches or so on the ground depending on which channel you are on.

[TNRIVERSIDE]

jackwmssr wrote:
I think I need the help of a Ford mechanic. My 2002 ford explorer 4.0 v6 automatic will not shift into any 4x4 positions. I have checked all the fuses that I can find, 1 under the dash and 2 under the hood. It does not make any sounds at all when I push the 4x4 buttons. It did not make any strange sounds the last I used it a few weeks ago. I have tried it moving and sitting still, in neutral with the brake on. I have had it since new and used it every winter so I am sure it is not operator error. It has 99000 miles on it. Now for a little recent history. I had the cables disconnected to clean the post 3 weeks ago. Two days later I used a homeowner style alternator tester to check the alternator (good). I jumped the MH last week to start it, all of these since the last time used the 4x4. While doing the above I never did hook any thing up wrong. THE FORECAST IS CALLING FOR SNOW tonight 7 to 9 inches. I would be very thankful if some one can help me with this.

So jackwmssr, let us know the outcome.

[Okie1]

Same here, It seems like the key is to put it in four wheel drive every couple of weeks to keep everything free. A slight tap has worked for me several times....

dlk wrote:
First off is it the shift on the fly 4x4, if it is you can try this, don't ask me how I know. On the transfer case, drivers side is an electronic servo motor that shifts the unit from 4 hi or low, mine used to not work at times, I took a rubber mallet and gave it a couple of whacks and guess what it worked again, your out nothing but a few minutes of time to see if it works.

[tenbear]

My '06 Ranger had the same problem. Ford replaced some motor under warranty and that fixed it. I have no idea where the motor is, probably the same motor dlk mentioned.

[Sloop_Smitten]

Thanks Mex!

[MEXICOWANDERER]

Sloop Smitten wrote:
What Dan indicated is a well known problem with the transfer case shift servo. It rotates to the end of play where they installed nylon bushings that get crushed over time. When that happens the servo loses its place and you have to remove it and reposition the internal components. If you do a search on any of the online Explorer forums they have it pretty well documented. I had to do it on my old Explorer as well. You might check the plug at the servo as well and make sure it has not been damaged or disconnected.

Kudos for a IMHO a 5-Star response.

[nettech207]

you might have a clog vacuum line ford shift on the fly used vacuum hoses to switch between 2 and 2 wheel drive, or the electronic shift module could be bad. I would bring it to a ford guy he should be able to pinpoint the problem pretty quickly

[Sloop_Smitten]

What Dan indicated is a well known problem with the transfer case shift servo. It rotates to the end of play where they installed nylon bushings that get crushed over time. When that happens the servo loses its place and you have to remove it and reposition the internal components. If you do a search on any of the online Explorer forums they have it pretty well documented. I had to do it on my old Explorer as well. You might check the plug at the servo as well and make sure it has not been damaged or disconnected.

[Turbo_Diesel_Du]

I'd go with dlk. Quite possibly the shaft on the electric servo motor may be frozen/rusty or a wire is broken.

[dlk]

First off is it the shift on the fly 4x4, if it is you can try this, don't ask me how I know. On the transfer case, drivers side is an electronic servo motor that shifts the unit from 4 hi or low, mine used to not work at times, I took a rubber mallet and gave it a couple of whacks and guess what it worked again, your out nothing but a few minutes of time to see if it works.

[TNRIVERSIDE]

Looks like you have tried the most likely. I have had a Ford that had the shift linkage that got out of adjustment and the 4X4 would not sift. I found that if I positioned the shift leaver a little off neutral but not fully into D or R it would shift. Its worth a try. Good luck.