Transfer case stays in 4wd - Explorer Ford Cars & Trucks

Which of these does your vehicle have
Transfer Case - NVG 126-NP4
Transfer Case - NVG 226-NP8
Do you know what a RPO code is ? Where it's located on the vehicle ? RPO code NP4 or NP8 will tell you which transfer case your's has . Vacuumn has nothing to do with it . controlled electroniclly . Having a professional scan tool hooked up an DTC'S - diagnostic trouble codes check is what you should do .

The production/process codes provide the description of the Regular Production Options (RPOs) used on the vehicle. The RPO list is printed on the Service Parts Identification Label. The following is a list of the RPO abbreviations and the description of each:
NP4
Transfer Case Active Single Speed All Wheel Drive (AWD)
NP5
Steering Wheel Leather Wrapped
NP7
Steer Column EEC Approved
NP8
Transfer Case Active All Wheel Drive (AWD) 2 Speed

SERVICE 4WD indicator
The SERVICE 4WD indicator is an integral part of the cluster and cannot be serviced separately. This lamp is used to inform the driver of the vehicle that a transfer case system malfunction. The SERVICE 4WD indicator is controlled by the transfer case shift control module via Class 2.

Sounds like the rod from the 4WD shifter has come loose form the transfer case or from the shifter lever. Some use a cable. Look under the vehicle. A rod or cable will go from the shifter to the transfer case. If it is a cable and the ends appear attached the cable is broken inside the housing. Reattach ends of rod or replace cable .

1. • 1 Start your Dodge truck's engine.
     
   • 2 Turn the electronic transfer case from "2WD" to "4WD Lock" to engage the high range 4WD, if the dodge truck is equipped with an electronic transfer case; otherwise, shift the transfer case lever from "2H" to "4H." The electronic transfer case is located on the instrument panel and is marked with "2WD," "4WD Lock" and 4WD Low." The lever-equipped transfer case is located to the right of your leg and is marked with "2H," "4H" and "4L."
     
   • 3 Shift the transmission into "Neutral" while the vehicle is either stopped or rolling at 2 to 3 mph to begin engaging in the low range 4WD. Turn the electronic transfer case to "4WD Low," if the Dodge truck is equipped with an electronic transfer case; otherwise, shift the transfer case lever from "2H" or "4H" to "4L."
     
   Tips & Warnings
   • Indicator lights will come on and alert you that your vehicle is in either the high or low range of 4WD.
     
   • Do not engage in the low range of 4WD drive if the transmission is in gear; you must shift to "Neutral" first.
     
   • Many Dodge trucks allow you to shift from 2-wheel drive to the high range of 4WD at up to 55 mph--consult your truck's manual to ensure that this is possible. Do not exceed 55 mph while engaged in the high range of 4WD. Do not exceed 25 mph while engaged in the low range of 4WD.
     
   • Do not engage in 4WD unless you are on slipper or rocky roads.
     

Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide
Transfer Case Assembly - REMOVAL & INSTALLATION

Samurai Models
Even the 2WD Samurai uses a transfer case. Rather than use a straight line driveshaft from the transmission to the differential, the Samurai leaves the transfer case in place and replaces its internal working with a simple offset gear mechanism, thus keeping 2 of the 3 driveshafts used in the 4WD vehicle.

1. On 4WD vehicles, remove the transfer case shift lever.
2. Raise and support the vehicle safely.
3. Drain the oil from the transfer case.
4. Matchmark and remove the driveshafts from the transfer case assembly. Not all of the driveshafts need to be completely removed from the vehicle, just unbolted from the case flanges. In most cases, the shaft or shafts on one side of the transfer case can be repositioned and supported out of the way.
5. Support the transfer case using a suitable transmission jack.
6. Disconnect the speedometer cable from the transfer case.
7. On 4WD vehicles, disconnect the 4WD switch lead wire at the coupler.
8. Remove the three mounting bolts and/or nuts securing the transfer case to the chassis, as applicable.
9. Carefully lower the transfer case from the vehicle.

To install:

1. Position and install the transfer case. Tighten the mounting bolts to 159-248 inch lbs. (18-28 Nm) and/or the mounting nuts to 19-25 ft. lbs. (25-34 Nm).
2. On 4WD vehicles, connect the 4WD switch lead wire at the coupler.
3. Connect the speedometer cable to the transfer case.
4. Properly refill the transfer case with an approved type of gear oil.
5. Align and install the driveshafts to the transfer case.
6. On 4WD vehicles, install the transfer case shift lever.
7. Remove the jackstands and carefully lower the vehicle.

Sidekick, Tracker, Sidekick Sport and X-90 Models
On these models the transfer case is bolted to the transmission and takes the place of the 2WD transmission's extension housing. Therefore, transfer case is removed or installed as part of the transmission assembly.

Hope this help (remember rated this and comment).

THE TRANSFER CASE MOTOR IS NOT WORKING TO INGAGE 4 WHEEL DRIVE. CHECK WITH DOOR OPEN WHEN YOU PUSH 4 WHEEL SWITCH YOU SHOULD HEAR MOTOR INGAGE 4 WHEEL DRIVE. IF YOU HEAR MOTOR BUT STILL NO 4 WHEEL DRIVE THE GEAR ON MOTOR COULD BE DAMAGED. REPLACE TRANSFER CASE MOTOR.

Have you tried replacing the actuator switch?

the transfer case module is bad it is bolted to transfer case above front drive shaft

2-Speed Torque-On-Demand (TOD) Operation
The automatic 4-wheel drive (A4WD) system is a 2-speed torque-on-demand (TOD) operation that utilizes the following components:

• Transfer case
• 4-wheel drive (4WD) control module (integral to the powertrain control module [PCM])
• Mode select switch (MSS)
• Gearmotor encoder assembly (part of the transfer case shift motor)
• Transfer case shift motor
• Shift motor sense plate (part of the gearmotor encoder assembly)

Principles of Operation
Transfer Case Shift Motor The externally mounted transfer case shift motor, located at the rear of the transfer case, turns the shift cam assembly. As the shift cam assembly turns, it positions the reduction shift fork for desired transfer case operation. An integral position sensor in the shift motor provides shift motor position information to the 4WD control module.
Mode Select Switch (MSS) The push button MSS, mounted on the instrument panel, allows the operator to select the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the instrument cluster push button, will illuminate only when the 4x4 Low position is engaged.
Visual Inspection Chart Mechanical Electrical

• Axle shafts and CV joints
• Driveshaft and universal joints
• Fluid leaks
• Matching tire sizes
• Transfer case shift motor

• Battery junction box (BJB) fuses:
  • 8 (30A)
  • 17 (5A)
  • 18 (20A)
• Central junction box (CJB) fuses:
  • 12 (5A)
  • 24 (15A)
• 4x4 module (PCM)
• Wiring harness
• Gearmotor encoder contact plate
• Connector(s)
• Circuitry
• Mode indication switch (MSS)

1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

1. If the concern is not visually evident, connect the diagnostic tool to the data link connector and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle:
   • check that the program card is correctly installed.
   • check the connections to the vehicle.
   • check the ignition switch position.

1. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual.

1. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
   • CAN circuit fault; all electronic control units no response/not equipped, refer to Section 418-00 .
   • No response/not equipped for 4WD module (PCM), Go To Pinpoint Test G .
   • System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out the 4WD module (PCM) self test.

1. If the DTCs retrieved are related to the concern, go to the 4WD Control Module (PCM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 4WD Control Module (PCM) Diagnostic Trouble Code (DTC) Index
   DTC Description Source Action B1317 Battery Voltage HIGH 4WD Module (PCM) REFER to Section 414-00 . B1318 Battery Voltage LOW 4WD Module (PCM) REFER to Section 414-00 . B1319 Driver Door Ajar Circuit Failure 4WD Module (PCM) Go To Pinpoint Test M . B1322 Driver Door Ajar Circuit Short To Ground 4WD Module (PCM) Go To Pinpoint Test M . B1342 ECU is Defective 4WD Module (PCM) CLEAR the DTCs. REPEAT the 4x4 module (PCM) self test. If DTC B1342 is retrieved, INSTALL a new 4x4 module (PCM). REFER to Section 303-14 . CLEAR the DTCs. REPEAT the self test. B1483 Brake Pedal Input Circuit Failure 4WD Module (PCM) Go To Pinpoint Test M . B1485 Brake Pedal Input Short to Battery 4WD Module (PCM) Go To Pinpoint Test M . C1729 Transfer Case Unable to Transition Between 4H and 4L 4WD Module (PCM) Go To Pinpoint Test K . C1970 4WD Low Mode Switch LED Short to Battery 4WD Module (PCM) Go To Pinpoint Test K . C1971 4WD Low Mode Switch LED Circuit Failure 4WD Module (PCM) Go To Pinpoint Test K . P1707 Transfer Case NEUTRAL or PARK/NEUTRAL Indication Circuit 4WD Module (PCM) Go To Pinpoint Test M . P1812 Transmission 4-Wheel Drive Mode Select Circuit Failure 4WD Module (PCM) Go To Pinpoint Test K . P1815 Transmission 4-Wheel Drive Mode Select Short Circuit to Ground 4WD Module (PCM) Go To Pinpoint Test K . P1816 Transmission NEUTRAL Safety Switch Circuit Failure 4WD Module (PCM) Go To Pinpoint Test M . P1819 Transmission NEUTRAL Safety Switch Circuit Short to Ground 4WD Module (PCM) Go To Pinpoint Test M . P1820 Transfer Case Clockwise Shift Relay Coil Circuit Failure 4WD Module (PCM) Go To Pinpoint Test K . P1822 Transfer Case Clockwise Shift Relay Coil Circuit Short To Battery 4WD Module (PCM) Go To Pinpoint Test K . P1824 4-Wheel Drive Clutch Relay Circuit Failure 4WD Module (PCM) Go To Pinpoint Test H . P1826 4-Wheel Drive Low Clutch Relay Short Circuit to Battery 4WD Module (PCM) Go To Pinpoint Test H . P1827 4-Wheel Drive Low Clutch Relay Short Circuit to Ground 4WD Module (PCM) Go To Pinpoint Test H . P1828 Transfer Case Counterclockwise Shift Relay Coil Circuit Failure 4WD Module (PCM) Go To Pinpoint Test K . P1830 Transfer Case Counterclockwise Shift Relay Coil Circuit Short To Battery 4WD Module (PCM) Go To Pinpoint Test K . P1849 Transfer Case Contact Plate A Short Circuit to Ground 4WD Module (PCM) Go To Pinpoint Test K . P1853 Transfer Case Contact Plate B Short Circuit to Ground 4WD Module (PCM) Go To Pinpoint Test K . P1857 Transfer Case Contact Plate C Short Circuit to Ground 4WD Module (PCM) Go To Pinpoint Test K . P1861 Transfer Case Contact Plate D Short Circuit to Ground 4WD Module (PCM) Go To Pinpoint Test K . P1867 Transfer Case Contact Plate General Circuit Failure 4WD Module (PCM) Go To Pinpoint Test K . P1891 Transfer Case Contact Plate Ground Return Open Circuit 4WD Module (PCM) Go To Pinpoint Test K . U1900 CAN Communication BUS Fault 4WD Module (PCM) REFER to Section 418-00 . U2023 External Node Fault 4WD Module (PCM) REFER to Section 418-00 . U2051 One Or More Calibration Files Missing/Corrupt 4WD Module (PCM) Reprogram/Reflash the 4x4 module. REFER to Section 418-00 . - For All Other DTCs 4WD Module (PCM) REFER to Section 418-00 .
2. Your best bet mite be to take it to a qualified repair shop !