Esof wiring diagram for 2002 f350

There's a module on top of the transmission the connections maybe corroded or that module has failed

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It seems that there is a battery draw that is shorting out the fuse. you need to trace the wire back to the point of power and see what is going on. My theory would be that some place in the power out (from the fuse) it is grounding to the chassis. I wouldn't even be able it give you and idea where to start considering how many wires there are, but if you can isolate that wire and chase it back to the cluster and the gauges you will find the issue.

The first things to check are the vacuum hoses going to the front knuckles, they are known to break and leak.You could have a broken hose, a bad vacuum solenoid, or something else causing a big vacuum leak when you engage the ESOF.

It's usually not a "hub going out". Check for broken vacuum lines from the vacuum solenoid on the passenger-side inner fender, going to a "T", and down to the front hubs. If you have one, use a hand-vacuum-pump to pull vacuum on the line going from the vacuum solenoid to the front hubs. If it holds vacuum, the vacuum solenoid needs to be replaced.

Is the system ESOF ( Electronic Shift On the Fly ) or MSOF ( Mechanical Shift On the Fly ) ?

Lift and support the front of the truck so the front wheels are off the ground ( take safety precautions, chock wheels, jack stands, etc )
Key on, engage 4x4 and try to turn the front drive shaft.
If it turns it is a problem with the transfer case.
If it doesn't it is a front axle engagement problem.

This section is specific to the New Body Style 2004 ( not the 2004 Heritage model ).
- If the front drive shaft does not turn :
Shut of the truck ( still jacked up, and supported ) remove the vac lines from the IWE. The spring should push the gears in, without the vac line on.
Check the vent line ( tube that is routed into the engine compartment with nothing attached to it ), for blockages.
If the vent line is clear, and with the vac lines off the IWE should be engaged ( both front wheels locked ).
If they lock, the problem is with the IWE solenoid not shutting off vacuum to the IWEs. There is a TSB on the 2004-2006 IWE solenoids, a newer revision has been made, and used from 2007 and newer MYs.

Here is a block diagram of the IWE system


If you have an ESOF system and the front drive shaft turns, try tapping on the transfer case, while someone turns the switch to 4H and 4L with a dead blow hammer ( not a metal hammer ). Some times the shift motor will get hung up and not shift. This will cause the truck not to cut vacuum to the IWE solenoids, and not confirm the action with the light on the range select switch.
Also, check the fuses for the ESOF system, should be fuses F111, F11, F29, F30. In the fuse panel under the hood, there is the clock wise and counter clock wise relays, pull them and bench test with a meter and external 12 VDC power supply for correct operation ( these are what turn the shift motor clock wise and counter clock wise ).

If you are following the procedure in the owners manual ( shift into Park or Neutral ) prior to shifting out of 4L, you can try 2 things.

1. Old school back up ~ 30' and then put into park and try shifting out of 4L. This is how it used to be done, and if the transfer case is binding, this can relieve the pressure.

2. If you have an ESOF ( Electronic Shift On the Fly ) 4x4, you can have someone turn the range select switch while tapping on the back of the transfer case with a dead blow hammer ( do not use a metal hammer, could damage the case ). This is to see if the ESOF shift motor is held up.

The truck when into 4L Ok, so I would assume power is to the transfer case, but it could be a contact plate issue, where the truck is trying to shift out, and the contact plate is not signaling the GEM ( Generic Electronic Module ) that the transfer case is in 2WD mode, and unlock the front axle / change the range switch to 2W indicator ).

Pot back what you find out, and if you have a ESOF or MSOF ( Manual / Mechanical Shift On the Fly i.e transfer case lever ).

Is the system ESOF ( Electronic Shift On the Fly ) or MSOF ( Mechanical Shift On the Fly ) ?

Operationally vacuum holds the IWE ( Integrated Wheel Ends ) out, and once vac is removed the spring engages the IWE.

Lift and support the front of the truck so the front wheels are off the ground ( take safety precautions, chock wheels, jack stands, etc )
Key on, engage 4x4 and try to turn the front drive shaft.
If it turns it is a problem with the transfer case. Check the fuse for the shift motor ( if ESOF ) & the connector to the transfer case ( some get gummed up with oil & road dirt ) that the pins are clean, and making contact.
If it doesn't it is a front axle engagement problem.

- If the front drive shaft does not turn :
Shut of the truck ( still jacked up, and supported ) remove the vac lines from the IWE. The spring should push the gears in, without the vac line on.
Check the vent line ( tube that is routed into the engine compartment with nothing attached to it ), for blockages.
If the vent line is clear, and with the vac lines off the IWE should be engaged ( both front wheels locked ).
If they lock, the problem is with the IWE solenoid not shutting off vacuum to the IWEs. There is a TSB on the 2004-2006 IWE solenoids, a newer revision has been made, and used from 2007 and newer MYs.

Here is a block diagram of the IWE system

Is the system ESOF ( Electronic Shift On the Fly ) or MSOF ( Mechanical Shift On the Fly ) ?

Operationally vacuum holds the IWE ( Integrated Wheel Ends ) out, and once vac is removed the spring engages the IWE.
Usually the problem ( with 04-08 MY ) is the front axle will not disengage.

Lift and support the front of the truck so the front wheels are off the ground ( take safety precautions, chock wheels, jack stands, etc )
Key on, engage 4x4 and try to turn the front drive shaft.
If it turns it is a problem with the transfer case.
If it doesn't it is a front axle engagement problem.

- If the front drive shaft does not turn :
Shut of the truck ( still jacked up, and supported ) remove the vac lines from the IWE. The spring should push the gears in, without the vac line on. Actually any time the truck is not running, after the vacuum bleeds out, the front IWEs will engage while it is parked.

Here is a block diagram of the IWE system


If the front axle turns, the shift motor ( on the ESOF ) would be the issue. Some times the connector on the back of the transfer case gets corroded and needs to be cleaned. Other problems could be a hung up shift motor, some have tapped on the back of the transfer case to free it up again.

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