4x4 won't disengage but light not on. - Diesel Forum - TheDieselStop.com
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99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the 99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

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Old 03-09-2012, 02:32 PM   #1 (permalink)
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4x4 won't disengage but light not on.

Hey guys, I drove my brothers truck (2001 f250 diesel, 6 speed) to work this morning and noticed it was vibrating a lot. When I got to work I tried to spin in snow and realized it was in 44wd. The light is not on nor does it come on when I turn the switch to 4wd. It's not my truck so I'm not 100 percent sure the light works. any idea's where to start? I checked the 30amp fuse but can't find any relays for it.
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2004 CREW CAB PSD, no mods, 305/70/16R wrangler MTR.
1985 ford f-250 4x4 6.9l sc "the beast"
4" lift, 35" toyo mud terrain's, Ip turned up, stacks
http://photos.thedieselstop.com/show...hp?photo=18913
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Old 03-09-2012, 02:43 PM   #2 (permalink)
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unlock the hub caps
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2000 F-250 7.3, Short Bed, Ext Cab,
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Old 03-09-2012, 02:45 PM   #3 (permalink)
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They are already in auto and that wouldn't make the transfer case stay engaged.
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2004 CREW CAB PSD, no mods, 305/70/16R wrangler MTR.
1985 ford f-250 4x4 6.9l sc "the beast"
4" lift, 35" toyo mud terrain's, Ip turned up, stacks
http://photos.thedieselstop.com/show...hp?photo=18913
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Old 03-09-2012, 09:15 PM   #4 (permalink)
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So i've established that the light functions, the 30amp maxi fuse is good. No power to what i'm thinking is the motor at any setting on switch with key on engine off.
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2004 CREW CAB PSD, no mods, 305/70/16R wrangler MTR.
1985 ford f-250 4x4 6.9l sc "the beast"
4" lift, 35" toyo mud terrain's, Ip turned up, stacks
http://photos.thedieselstop.com/show...hp?photo=18913
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Old 03-12-2012, 01:21 AM   #5 (permalink)
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You have two relays under the hood on the driver side near the firewall that control the shift motor on the t case, the relays are powered at all times and the gem module gives the ground when shifting in and out of four wheel drive.
If your problem is the same as what I've had happen to me on two different trucks the grounding wire going from the gem module to the relay gets a nick in the insulation and goes green thus no longer conducts.
You can jumper the ground to the relay to test my theory and if the t case shifts you know you've found the problem.
Get the wiring diagram so you know what wire to ground.
The wires that ground the relays are smaller dia than the power wires, I think the one that was bad on mine was a brown wire with a white tracer, there is more than one brown/with white tracer so make shure you have the right one.
Good luck, I spent several hours chasing this problem to find one bad wire.
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Old 03-12-2012, 10:47 PM   #6 (permalink)
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I pulled both relays towards front and left them out for a minute while i read owners manual. Put them back in and it worked fine. Thanks for the reply
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2004 CREW CAB PSD, no mods, 305/70/16R wrangler MTR.
1985 ford f-250 4x4 6.9l sc "the beast"
4" lift, 35" toyo mud terrain's, Ip turned up, stacks
http://photos.thedieselstop.com/show...hp?photo=18913
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Old 07-06-2014, 10:40 AM   #7 (permalink)
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help!!!

hey I have a 99 that the dash lights prove themselves but the 4x4 stays on and the transfer case wont shift and the relay box lost its cover and mount so i found it hanging down by the frame the contacts are all green i tried cleaning them but no luck i plow snow so i kinda need it to work thanks for any input
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