Ford 1998 Expedition Workshop Manual

Transfer Case

Refer to Wiring Diagrams Cell 34 (Expedition, Navigator), All-Wheel Drive for schematic and connector information.

Refer to Wiring Diagrams Cell 59 (Expedition, Navigator), Generic Electronic Module for schematic and connector information.

A4WD Vacuum Schematic

Table 1 — 4WD Mode Switch Input Resistances

Table 2 — 4x4 Shift Motor Relay Outputs

SECTION 308-07A: Transfer Case — General Information 1998 Expedition/Navigator Workshop Manual

DIAGNOSIS AND TESTING

Procedure revision date: 05/06/2002

Special Tool(s)

Digital Multimeter

418-F082 (105-R0005)1 or equivalent

New Generation STAR (NGS) Tester

418-F048 (007-00500) or equivalent

Vacuum Pump

416-D001 (D83L-7059-A) or equivalent

Mode Switch Position Resistance (Ohms)

2WD 3700-4100

A4WD 1400-1600

4WD HIGH 645-715

4WD LOW 225-255

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Table 3 — Neutral Safety Switch Input Conditions

Table 4 — Contact Plate Sensor Position Codes

*

Refers to the code at the point of transition between two positions or areas of the sensor.

*

Refers to the code at the point of transition between two positions or areas of the sensor.

Inspection and Verification

1. Verify the customer concern by operating the 2WD/4WD engagement.

2. Visually inspect for obvious signs of mechanical, electrical and vacuum damage; refer to the following chart:

Visual Inspection Chart

3. If the concern remains after the inspection connect the New Generation STAR (NGS) Tester to the data link connector (DLC) located beneath the instrument panel and select the

vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle:



Check that the program card is properly installed.



Check the connections to the vehicle.



Check the ignition switch position.

4. If the NGS still does not communicate with the vehicle, refer to the New Generation STAR Tester manual.

5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:



CKT 914, CKT 915 OR CKT 70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418-00.



NO RESP/NOT EQUIP for Generic Electronic Module (GEM), go to Pinpoint Test E.



SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM.

6. If the DTCs retrieved are related to the concern, go to GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics.

7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.

GEM Diagnostic Trouble Code (DTC) Index

HI-to-LO LO-to-HI Mode

GROUND B+ 4 HIGH to 4 LOW

B+ GROUND 4 LOW to 4 HIGH

GROUND GROUND Brake Motor

Transmission State Start/Clutch Depressed Input Transmission Range Sensor Input

In Gear Open Open

Park Ground Open

Neutral Ground Ground

(Start) Park Battery Voltage Open

(Start) Neutral Battery Voltage Ground

Contact Plate Code Left Mech.Stop Left Stop A4WD/2H 2H E

*

4H E 4H 4L E

*

4L Right Mech.Stop

A Closed Closed Closed Closed Closed Open Open Open Closed

B Open Open Open Closed Closed Closed Closed Closed Closed

C Open Closed Closed Closed Closed Closed Closed Open Open

D Open Open Closed Closed Open Open Closed Closed Closed

Mechanical Electrical



Switch(es)



Vacuum leaks



Fuse(s)



Damaged wiring harness



Loose or corroded connector(s)



Circuitry

DTC Test Mode Description Section

B1214 Continuous, On-

Demand

Running board lamp relay coil open or short to ground. REFER to Section 417-02.

B1215 Continuous, On-

Demand

Running board lamp relay coil short to power. REFER to Section 417-02.

B1240 Continuous Rear washer pump relay coil open or short to ground. REFER to Section 501-16.

B1241 Continuous Rear washer pump relay coil short to power. REFER to Section 501-16.

B1302 Continuous, On-

Demand

Accessory delay relay coil open or short to ground. (Only set if battery saver relay

has no faults.)

REFER to Section 501-11.

B1304 Continuous, On-

Demand

Accessory delay relay coil short to power. REFER to Section 501-11.

B1313 Continuous, On-

Demand

Battery saver relay coil open or short to ground. REFER to Section 417-02.

B1315 Continuous, On-

Demand

Battery saver relay coil short to power. REFER to Section 417-02.

B1317 Continuous, On- Battery voltage HIGH, greater than 18.0 volts. REFER to Section 414-02.

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Demand

B1318 Continuous, On-

Demand

Battery voltage LOW, less than 10 volts. REFER to Section 414-02.

B1322 On-Demand LF door open warning circuit short to ground, or door open. REFER to Section 417-02.

B1323 Continuous, On-

Demand

Door open warning lamp open or short to ground. REFER to Section 413-01.

B1325 Continuous, On-

Demand

Door open warning lamp short to power. REFER to Section 413-01.

B1330 On-Demand RF door open warning circuit short to ground, or door open. REFER to Section 417-02.

B1334 On-Demand Liftgate or liftgate glass door open warning circuit short to ground, or door open. REFER to Section 417-02

B1338 On-Demand RR door open warning circuit short to ground, or door open. REFER to Section 417-02.

B1342 Continuous, On-

Demand

ECU is defective, RAM/ROM checksum failure. REPLACE the GEM. REFER to Section 419-10.

B1345 Continuous, On-

Demand

Heated backlite input circuit short to ground. REFER to Section 501-11.

B1347 Continuous, On-

Demand

Heated grid relay coil circuit open or short to ground. REFER to Section 501-11.

B1349 Continuous, On-

Demand

Heated grid relay coil short to battery. REFER to Section 501-11.

B1352 Continuous, On-

Demand

Key-in-ignition circuit open. REFER to Section 413-09.

B1355 On-Demand Ignition RUN circuit open. REFER to Section 211-05.

B1359 Continuous, On-

Demand

Ignition RUN/ACC circuit open. REFER to Section 211-05.

B1365 Continuous, On-

Demand

Ignition START circuit short to power. REFER to Symptom Chart for customer concern.

B1371 Continuous, On-

Demand

Interior lamp relay coil open or short to ground. REFER to Section 417-02.

B1373 Continuous, On-

Demand

Interior lamp relay coil short to power. REFER to Section 417-02.

B1398 Continuous, On-

Demand

LF one-touch down power window relay coil open or short to ground. REFER to Section 501-11.

B1400 Continuous, On-

Demand

LF one-touch down power window relay coil short to power. REFER to Section 501-11.

B1405 On-Demand LF power window switch down circuit short to power. REFER to Section 501-11.

B1408 On-Demand LF power window switch up circuit short to power. REFER to Section 501-11.

B1410 Continuous, On-

Demand

LF power window motor excessive current draw. REFER to Section 501-11.

B1426 Continuous, On-

Demand

Seat belt lamp circuit short to power. REFER to Section 413-01.

B1428 Continuous, On-

Demand

Seat belt lamp circuit open or short to ground. REFER to Section 413-01.

B1431 Continuous Front wiper RUN/PARK relay coil circuit open or short to ground. REFER to Section 501-16.

B1432 Continuous Front wiper RUN/PARK relay coil circuit short to power. REFER to Section 501-16.

B1434 Continuous Front wiper HI/LO speed relay coil circuit open or short to ground. REFER to Section 501-16.

B1436 Continuous Front wiper HI/LO speed relay coil circuit short to power. REFER to Section 501-16.

B1438 Continuous, On-

Demand

Front wiper mode select switch open or short to power. REFER to Section 501-16.

B1441 On-Demand Front wiper mode select switch circuit short to ground. REFER to Section 501-16.

B1445 On-Demand Door handle switch circuit short to ground or handle. REFER to Section 417-02.

B1446 Continuous Front wiper motor PARK sense circuit short to ground. REFER to Section 501-16.

B1450 Continuous, On-

Demand

Front wiper interval delay switch circuit open or short to power. REFER to Section 501-16.

B1453 Continuous Front wiper interval delay switch circuit short to ground for greater than 20 seconds. REFER to Section 501-16.

B1453 On-Demand Wiper interval delay switch circuit short to ground. REFER to Section 501-16.

B1454 Continuous, On-

Demand

Low washer fluid warning indicator output circuit open or short to ground. REFER to Section 501-16.

B1456 On-Demand Low washer fluid warning indicator output circuit short to power. REFER to Section 501-16.

B1458 Continuous Front washer pump motor relay coil circuit open or short to ground. REFER to Section 501-16.

B1460 Continuous Front washer pump motor relay coil short to power. REFER to Section 501-16.

B1462 On-Demand Seat belt switch open circuit. REFER to Section 413-09.

B1466 On-Demand Front wiper HI/LO speed not switching. REFER to Section 501-16.

B1467 Continuous Front wiper HI/LO speed motor circuit short to power. REFER to Section 501-16.

B1473 On-Demand Front wiper LO speed motor circuit failure (wiper energized and park sense not

seen).

REFER to Section 501-16.

B1475 Continuous, On-

Demand

Delayed accessory relay contacts short to power. REFER to Section 501-11.

B1476 On-Demand Front wiper HI speed motor circuit failure (wiper energized and park sense not seen). REFER to Section 501-16.

B1483 Continuous Brake pedal input open circuit. (No brake input seen for 8 ignition cycles.) GO to Pinpoint Test C.

B1485 Continuous Brake pedal input circuit short to battery. GO to Pinpoint Test C.

B1574 On-Demand LR door open warning circuit short to ground or door open. REFER to Section 417-02.

B1577 On-Demand Headlamp/parking lamp input circuit short to power. REFER to Section 413-09.

B1610 On-Demand Illuminated entry input short to ground. REFER to Section 417-02.

B1611 Continuous, On-

Demand

Rear wiper mode select switch circuit open or short to battery. REFER to Section 501-16.

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GEM Parameter Identification (PID) Reference Chart

B1614 On-Demand Rear wiper mode select switch circuit short to ground. REFER to Section 501-16.

B1814 Continuous, On-

Demand

Rear wiper DOWN relay coil open or short to ground. REFER to Section 501-16.

B1816 Continuous Rear wiper DOWN relay coil short to power. REFER to Section 501-16.

B1818 Continuous, On-

Demand

Rear wiper UP relay coil open or short to ground. REFER to Section 501-16.

B1820 Continuous Rear wiper UP relay coil short to power. REFER to Section 501-16.

B1839 Continuous Rear wiper motor circuit failure. (Relays have no faults and no motor movement

detected.)

REFER to Section 501-16.

B1840 Continuous Front wiper power circuit failure. REFER to Section 501-16.

C1107 Continuous ABS active fault (ABS event exceeding 2 minutes detected). GO to Pinpoint Test A.

P0500 Continuous Vehicle speed signal not detected for 21 ignition START cycles. REFER to Section 310-03. REFER to Symptom Chart for customer

concern.

P1804 Continuous, On-

Demand

4-Wheel drive HI indicator open or short to ground. REFER to Section 413-01.

P1806 Continuous, On-

Demand

4-Wheel drive HI indicator short to power. REFER to Section 413-01.

P1808 Continuous, On-

Demand

4-Wheel drive LO indicator open or short to ground. REFER to Section 413-01.

P1810 Continuous, On-

Demand

4-Wheel drive LO indicator short to power. REFER to Section 413-01.

P1812 Continuous, On-

Demand

4-Wheel drive mode select switch open or short to power. REFER to Symptom Chart for customer concern.

P1815 Continuous, On-

Demand

4-Wheel drive mode select switch circuit short to ground. REFER to Symptom Chart for customer concern.

B1819 On-Demand Neutral safety switch input short to ground. REFER to Symptom Chart for customer concern.

P1820 Continuous, On-

Demand

Transfer case LO to HI shift relay coil open or short to ground. REFER to Symptom Chart for customer concern.

P1822 Continuous Transfer case LO to HI shift relay coil short to power. GO to Pinpoint Test B.

P1824 Continuous, On-

Demand

4-Wheel drive electric clutch relay open or short to ground. GO to Pinpoint Test A.

P1826 Continuous 4-Wheel drive electric clutch relay short to power. GO to Pinpoint Test A.

P1828 Continuous, On-

Demand

Transfer case HI to LO shift relay open or short to ground. GO to Pinpoint Test B.

P1830 Continuous Transfer case HI to LO shift relay short to power. GO to Pinpoint Test B.

P1832 Continuous Front axle 4-wheel drive solenoid open or short to ground. GO to Pinpoint Test D.

P1834 Continuous, On-

Demand

Front axle 4-wheel drive solenoid short to power. GO to Pinpoint Test D.

P1836 Continuous Transfer case front shaft speed sensor not detected or not within range. GO to Pinpoint Test A.

P1837 Continuous Transfer case rear shaft speed sensor not detected or not within range. GO to Pinpoint Test A.

P1838 Continuous Transfer case shift motor fails to move. (Energized relays, motor does not move.) REFER to Symptom Chart for customer concern.

P1846 Continuous Transfer case contact plate A open circuit. REFER to Symptom Chart for customer concern.

P1850 Continuous Transfer case contact plate B open circuit. REFER to Symptom Chart for customer concern.

P1854 Continuous Transfer case contact plate C open circuit. REFER to Symptom Chart for customer concern.

P1858 Continuous Transfer case contact plate D open circuit. REFER to Symptom Chart for customer concern.

P1866 Continuous Transfer case system concern, contact plate failure. REFER to Symptom Chart for customer concern.

P1867 Continuous Transfer case contact plate open or short to ground. REFER to Symptom Chart for customer concern.

P1868 Continuous, On-

Demand

Automatic 4-wheel drive indicator circuit open or short to ground. REFER to Section 413-01.

P1869 Continuous, On-

Demand

Automatic 4-wheel drive indicator circuit short to power. REFER to Section 413-01.

P1874 On-Demand Hall effect sensor power short to ground. GO to Pinpoint Test A.

P1875 On-Demand Hall effect sensor power short to power. REFER to Symptom Chart for customer concern.

P1876 Continuous, On-

Demand

Transfer case 2-wheel drive solenoid open or short to ground. GO to Pinpoint Test D.

P1877 Continuous, On-

Demand

Transfer case 2-wheel drive solenoid short to power. GO to Pinpoint Test D.

P1886 Continuous 4x4 initialization failure (front driveline did not synchronize to rear). GO to Pinpoint Test A.

P1891 Continuous, On-

Demand

Transfer case contact plate ground return open circuit. REFER to Symptom Chart for customer concern.

PID Circuit Circuit Description Expected Values

BATSAV Fuse Junction Panel (Internal) Battery Saver Relay Circuit ON---, OFF---, ON-B-, OFFO-G

BOO_GEM 210 (LB) Brake Pedal Position (BPP) Switch Input ON, OFF

CLTCHSW — Clutch Pedal Position Switch ENGAGD, notEGD

DRAJAR 433 (DG/O) Door Ajar Indicator Circuit ON ---, OFF ---, ON-B-, OFFO-G

D_DR_SW 344 (BK/Y) LH Door Open Warning Lamp Switch AJAR, CLOSED

D_SBELT 85 (BR/LB) LH Safety Belt ON, OFF

HALLPWR 774 (LG) Hall Effect Speed Sensor Power ON---, OFF---, ON-B-, OFFO-G

ILLE_SW 1013 (BR/LG) Illuminated Entry Input (From RAP Module) ON, OFF

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Symptom Chart

IGN_GEM 297 (BK/LG), 1040 (R/LB), 32 (R/LB), 687 (GY/Y) Ignition Switch States START, RUN, OFF, ACC

IGN_KEY 158 (BK/PK) Ignition Key-In/Out IN, OUT

INTLMP 402 (O/LG) Fuse Junction Panel (Internal) Interior Lamp Relay Circuit ON---, OFF---, ON-B-, ON O-G

LGATE_SW 700 (W/PK) Liftgate/Glass Switch Status AJAR, CLOSED

LRDR_SW 363 (BK/LB) LR Door Open Warning Lamp Switch AJAR, CLOSED

MTR_CCW 781 (O/LB) HI to LO Shift Relay Coil Status ON---, OFF---, ON-B-, OFFO-G

MTR_CW 782 (BR/W) LO to HI Shift Relay Coil Status ON---, OFF---, ON-B-, OFFO-G

NTRL_SW 463 (R/W) Transmission Range Sensor Input NTRL, not NTRL

P_DR_SW 345 (BK/PK) RH Door Open Warning Lamp Switch AJAR, CLOSED

PARK_SW 257 (W/R) Headlamp Control Input Switch ON - OFF

PLATE_A 771 (P/Y) Transfer Case Contact Plate Switch A OPEN, CLOSED

PLATE_B 770 (W) Transfer Case Contact Plate Switch B OPEN, CLOSED

PLATE_C 764 (BR/W) Transfer Case Contact Plate Switch C OPEN, CLOSED

PLATE_D 763 (O/W) Transfer Case Contact Plate Switch D OPEN, CLOSED

PLATEPW 762 (Y/W) Contact Plate Ground Output ON---, OFF---, ON-B-, OFFO-G

PWR_RLY 239 (W/O) ABS Active Input (A4WD Only) ON, OFF

R_WP_DN 592 (T) Rear Wiper DOWN Relay Status ON---, OFF---, ON-B-, OFF O-G

R_WP_MD 485 (PK/BK) Rear Wiper Mode Switch Status LOW, HIGH, WASH, OFF

R_WP_PK 587 (P/Y) Rear Wiper Park Sense PARK, notPRK

R_WP_SW 488 (DG) Rear Washer Relay Output ON---, OFF---, ON-B-, OFFO-G

R_WP_UP 591 (LG) Rear Wiper UP Relay Status ON---,OFF---, ON-B-, OFFO-G

RB_LMP 1008 (LG/O) Running Board Lamp Output Status OFF---, ON---, OFFO-G, ON-B-

RRDR_SW 346 (BK/W) RR Door Open Warning Lamp Switch AJAR, CLOSED

SBLTLMP 450 (DG/LG) Safety Belt Warning Indicator ON ---, OFF ---, ON-B-, OFFO-G

SPEEDWP N/A Speed Dependent Wiper Function ACTIVE, notACT

TRA_FSP 435 (Y/LB) Front Shaft Speed 0-225 KPH

TRA_RSP 772 (LB) Rear Shaft Speed 0-255 KPH

VSS_GEM 676 (PK/O), 679 (GY/BK) Vehicle Speed Sensor 0-255 KPH

WASH_SW 686 (T/R) Front Washer Relay Output ON---, OFF---, ON-B-, OFFO-G

WFL_LMP 82 (PK/Y) Low Washer Fluid Warning Indicator Circuit ON---, OFF---, ON-B-, OFFO-G

WFLUID 81 (R/LG) Low Washer Fluid Switch LOW, OK

WPHISP 647 (GY/LB) Front Wiper HI/LO Relay Status ON---, OFF---, ON-B-, OFFO-G

WPMODE 680 (LB/O), 684 (PK/Y) Front Wiper/Washer Switch Status WASH, OPEN, INVLD, OFF, INTVL1-7, LOW, HIGH

WPPK_PK N/A Front Wiper Park to Park Time 0 to 65 seconds

WPPRKSW 671 (LB) Front Wiper Motor Switch Status PARKED, not PRK

WPRUN 646 (Y/W) Front Windshield Wiper Run/Park Relay Status ON---, OFF---, ON- B-, OFFO-G

2WDSOL 145 (GY/BK) 2WD Solenoid Status ON---, OFF---, ON-B-, OFFO-G

4WD_LMP 994 (W) A4WD Indicator Status ON---, OFF---, ON-B-, OFFO-G

4WDCLST 976 (O) Four Wheel Drive Clutch Relay Control ON---, OFF---, ON-B-, OFFO-G

4WDHIGH 777 (Y) 4WD High Indicator Status ON---, OFF---, ON-B-, OFFO-G

4WDLOW 778 (O) 4WD Low Indicator Status ON---, OFF---, ON-B-, OFFO-G

4WDSGEM 780 (DB) 4WD Mode INVLD, A42D, 2WD, 4WDLOW, 4WDHIGH, OFFO-G

4WDSOL 605 (R) 4WD Solenoid Status ON---, OFF---, ON-B-, OFFO-G

Symptom Chart

Condition Possible Sources Action



The A4WD Indicator Flashes When the A4WD Mode Is Selected



A4WD clutch relay/circuit.



Hall effect speed sensors/circuits.



Transfer case electric clutch.



4WABS module/circuit.



GEM.



GO to Pinpoint Test

A.



The Vehicle Does Not Shift Between 2WD/A4WD and 4WD Modes Properly



A4WD mode switch/circuit.



A4WD clutch relay/circuit.



Contact plate sensors A, B, C and/or D

circuits.



Transfer case shift motor/circuit.



Transfer case shift relays.



Transfer case mechanism.



GEM.



GO to Pinpoint Test

B.



The Vehicle Does Not Shift Between 4WD HIGH and 4WD LOW Modes

Properly



A4WD mode switch/circuit.



VSS.



BPP switch.



Transfer case shift relays.



Transfer case mechanism.



Transmission range sensor.



GEM.



Digital transmission range (DTR) sensor.



GO to Pinpoint Test

C.



The Front Axle Is Not Engaging Properly (Transfer Case Motor Movement

OK)



4x4 solenoid/circuit.



4x2 solenoid/circuit.



Vacuum motor.



Vacuum lines.



Front differential mechanism.



GO to Pinpoint Test

D.

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Pinpoint Tests

PINPOINT TEST A: A4WD INDICATOR FLASHES WHEN THE A4WD MODE IS SELECTED

NOTE: The vehicle has to be driven in A4WD 30 mph or greater and/or encounter a slip condition before the A4WD lamp will flash for certain faults.

NOTE: Complete the entire pinpoint test related to the symptom before replacing the GEM.



GEM.



No Communication With the Module — GEM



Fuses.



Circuitry.



GEM.



GO to Pinpoint Test

E.

CONDITIONS DETAILS/RESULTS/ACTIONS

A1 CHECK THE IGNITION STATES — MONITOR THE PID IGN_GEM

NGS

Monitor the PID IGN_GEM while turning the ignition switch through the START, RUN, OFF, and ACC positions.



Do the PID values agree with the ignition switch positions?

Yes

GO to A2.

No

REPAIR the ignition circuit (RUN/ACC: circuit 297 [BK/LG], RUN: circuit 687 [GY/Y], or START: circuit 32 [R/LB])

in question. CLEAR the DTCs. TEST the system for proper operation.

A2 RETRIEVE THE DIAGNOSTIC TROUBLE CODES (DTCS)

Retrieve Continuous DTCs

Clear Continuous DTCs

Retrieve On-Demand DTCs



Are any DTCs recorded?

Yes

If DTC B1342, REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal

operation.

If DTC P0500, GO to Pinpoint Test C.

If DTC P1483, GO to Pinpoint Test C.

If DTC P1485, GO to Pinpoint Test C.

If DTC P1804, REFER to Section 413-01.

If DTC P1806, REFER to Section 413-01.

If DTC P1808, REFER to Section 413-01.

If DTC P1810, REFER to Section 413-01.

If DTC P1812, GO to Pinpoint Test B or Pinpoint Test C.

If DTC P1815, GO to Pinpoint Test B or Pinpoint Test C.

If DTC P1820, GO to Pinpoint Test B.

If DTC P1822, GO to Pinpoint Test B.

If DTC P1824, GO to A19 .

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If DTC P1826, REPAIR all other DTCs first, then GO to A23 .

If DTC P1828, GO to Pinpoint Test B.

If DTC P1830, GO to Pinpoint Test B.

If DTC P1832, GO to Pinpoint Test D.

If DTC P1834, GO to Pinpoint Test D.

If DTC P1836, GO to A10 .

If DTC P1837, GO to A10 .

If DTC P1846, GO to Pinpoint Test B or Pinpoint Test C.

If DTC P1850, GO to Pinpoint Test B or Pinpoint Test C.

If DTC P1854, GO to Pinpoint Test B or Pinpoint Test C.

If DTC P1858, GO to Pinpoint Test B or Pinpoint Test C.

If DTC P1868, REFER to Section 413-01.

If DTC P1869, REFER to Section 413-01.

If DTC P1874, GO to A6 .

If DTC P1876, GO to Pinpoint Test D.

If DTC P1877, GO to Pinpoint Test D.

If DTC P1886, GO to A27 .

If DTC P1891, GO to Pinpoint Test B or Pinpoint Test C.

If DTC C1107, GO to A3 .

No

GO to A3.

A3 CHECK THE 4WABS MODULE INPUT; 4WABS MODULE CONNECTED — MONITOR THE PID PWR_RLY

Monitor the PID PWR_RLY.



Does the PID PWR_RLY indicate ON?

Yes

GO to A4.

No

GO to A6.

A4 CHECK THE 4WABS MODULE INPUT; 4WABS MODULE DISCONNECTED — MONITOR THE PID PWR_RLY

4WABS Module

Monitor the PID PWR_RLY.



Does the PID PWR_RLY indicate ON?

Yes

GO to A5.

No

REPLACE the 4WABS module; REFER to Section 206-09. CLEAR the DTCs. TEST the system for normal

operation.

A5 CHECK CIRCUIT 239 (W/O) FOR SHORT TO POWER

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GEM C240

Measure the voltage between GEM C240-1, circuit 239 (W/O), and ground.



Is any voltage indicated?

Yes

REPAIR circuit 239 (W/O). CLEAR the DTCs. TEST the system for normal operation.

No

REPLACE GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal operation.

A6 CHECK HALL EFFECT POWER CIRCUIT FOR SHORT TO GROUND — MONITOR THE PID HALLPWR

Place the mode switch in the A4WD position.

Monitor the PID HALLPWR.



Does the PID HALLPWR indicate OFF?

Yes

GO to A7.

No

GO to A10.

A7 CHECK THE HALL EFFECT CIRCUIT FOR SHORT TO GROUND — TRANSFER CASE ASSEMBLY C201 DISCONNECTED

Disconnect transfer case assembly C201 for Navigator or C111 for Expedition.

Cycle the ignition switch OFF then ON.

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Monitor the PID HALLPWR.



Does the PID HALLPWR indicate OFF?

Yes

GO to A9.

No

GO to A8.

A8 CHECK FRONT AND REAR HALL EFFECT SENSORS

Measure the resistance between transfer case assembly C201 pin 2, circuit 772 (LB) component side and

transfer case assembly C201 pin 6, circuit 682 (DB) component side; and between transfer case assembly C201

pin 4, circuit 435 (Y/LB) component side and transfer case assembly C201 pin 8, circuit 682 (DB) component

side.



Are the resistances less than 10,000 ohms?

Yes

If terminals 2 and 6 are less than 10,000 ohms, REPLACE rear Hall effect sensor. CLEAR the DTCs. TEST the

system for normal operation.

If terminals 4 and 8 are less than 10,000 ohms, REPLACE front Hall effect sensor. CLEAR the DTCs. TEST the

system for normal operation.

No

REPAIR circuit 774 (LG). CLEAR the DTCs. TEST the system for normal operation.

A9 CHECK CIRCUIT 774 (LG) FOR SHORT TO GROUND

GEM C241

Measure the resistance between transfer case assembly C201-3, circuit 774 (LG), and ground; and between

transfer case assembly C201-7, circuit 774 (LG), and ground.



Are the resistances greater than 10,000 ohms?

Yes

REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal operation.

No

REPAIR circuit 774 (LG). CLEAR the DTCs. TEST the system for normal operation.

A10 MONITOR THE FRONT AND REAR HALL EFFECT PIDS TRA_RSP AND TRA_FSP

Place the mode switch in the A4WD position.

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Monitor the PIDs TRA_RSP, TRA_FSP and VSS_GEM.

Drive the vehicle at 48 kph (30 mph) or greater.



Are the PIDs TRA_RSP and TRA_FSP within 3 kph (2 mph) of the VSS_GEM?

Yes

GO to A19.

No

If both PIDs TRA_RSP and TRA_FSP indicate 0 kph, GO to A11 .

If only one PID indicates 0 kph, GO to A14 .

If both PIDs indicate greater than 0 kph, but are not within 3 kph ( 2 mph) of each other, check for possible Hall

effect misalignment, or toothed wheel concern.

A11 CHECK THE VOLTAGE TO THE HALL EFFECT SENSORS — CIRCUIT 774 (LG)

Transfer Case Assembly C201

Measure the voltage between transfer case assembly C201-3, circuit 774 (LG), and ground; and between transfer

case assembly C201-7, circuit 774 (LG), and ground.



Are the voltages greater than 10 volts?

Yes

GO to A13.

No

GO to A12.

A12 CHECK CIRCUIT 774 (LG) FOR OPEN

GEM C241

Measure the resistance between transfer case assembly C201-3, circuit 774 (LG), and GEM C241-1, circuit 774

(LG); and between transfer case assembly C201-7, circuit 774 (LG), and GEM C241-1, circuit 774 (LG)

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

Are the resistances less than 5 ohms?

Yes

REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal operation.

No

REPAIR circuit 774 (LG). CLEAR the DTCs. TEST the system for normal operation.

A13 CHECK CIRCUIT 682 (DB) FOR OPEN

GEM C239

Measure resistance between transfer case assembly C201-6, circuit 682 (DB), and GEM C239-21, circuit 682

(DB); and between transfer case assembly C201-8, circuit 682 (DB), and GEM C239-21, circuit 682 (DB).



Are the resistances less than 5 ohms?

Yes

REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal operation.

No

REPAIR circuit 682 (DB). CLEAR the DTCs. TEST the system for normal operation.

A14 CHECK THE VOLTAGE TO THE HALL EFFECT SENSORS — CIRCUIT 774 (LG)

Transfer Case Assembly C201

If the rear Hall effect sensor is not indicating properly, measure the voltage between transfer case assembly

C201-3, circuit 774 (LG), and ground. If the front Hall effect sensor is not indicating properly, measure the voltage

between transfer case assembly C201-7, circuit 774 (LG), and ground.



Are the voltages greater than 10 volts?

Yes

GO to A15.

No

REPAIR circuit 774 (LG). CLEAR the DTCs. TEST the system for normal operation.

A15 CHECK THE HALL EFFECT SENSOR GROUND CIRCUITS 682 (DB) FOR OPEN

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GEM C239

If the rear Hall effect sensor is not indicating properly, measure the resistance between transfer case assembly

C201-6, circuit 682 (DB), and GEM C239-21, circuit 682 (DB). If the front Hall effect sensor is not indicating

properly, measure the resistance between transfer case assembly C201-8, circuit 682 (DB), and GEM C239-21,

circuit 682 (DB).



Are the resistances less than 5 ohms?

Yes

GO to A16.

No

REPAIR circuit 682 (DB). CLEAR the DTCs. TEST the system for normal operation.

A16 CHECK CIRCUIT 435 (Y/LB)/722 (LB) FOR OPEN

GEM C241

If the rear Hall effect sensor is not indicating properly, measure the resistance between transfer case assembly

C201-2, circuit 722 (LB), and GEM C241-5, circuit 722 (LB). If front Hall effect sensor is not indicating properly,

measure the voltage between transfer case assembly C201-4, circuit 435 (Y/LB) and GEM C241-6, circuit 435

(Y/LB).



Are the resistances less than 5 ohms?

Yes

GO to A17.

No

REPAIR circuit 722 (LB)/435 (Y/LB). CLEAR the DTCs. TEST the system for normal operation.

A17 CHECK CIRCUIT 435 (Y/LB)/772 (LB) FOR SHORT TO GROUND

If the rear Hall effect sensor is not indicating properly, measure the resistance between transfer case assembly

C201-2, circuit 772 (LB), and ground. If the front Hall effect sensor is not indicating properly, measure the

resistance between transfer case assembly C201-4, circuit 435 (Y/LB), and ground.



Are the resistances greater than 10,000 ohms?

Yes

GO to A18.

No

REPAIR circuit 435 (Y/LB)/772 (LB). CLEAR the DTCs. TEST the system for normal operation.

A18 CHECK CIRCUIT 435 (Y/LB)/772 (LB) FOR SHORT TO POWER

If the rear Hall effect sensor is not indicating properly, measure the voltage between transfer case assembly

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C201-2, circuit 772 (LB), and ground. If the front Hall effect sensor is not indicating properly, measure the voltage

between transfer case assembly C201-4, circuit 435 (Y/LB), and ground.



Is any voltage indicated?

Yes

REPAIR circuit 435 (Y/LB)/772 (LB). CLEAR the DTCs. TEST the system for normal operation.

No

REPLACE the inoperative Hall effect sensor(s). CLEAR the DTCs. TEST the system for normal operation. If

concern still exists, REPLACE the GEM; REFER to Section 419-10. TEST the system for normal operation.

A19 MONITOR THE A4WD CLUTCH RELAY PID 4WDCLST

Monitor the PID 4WDCLST.

Place the mode switch in the A4WD position.



Does the PID 4WDCLST indicate ON--- when in the A4WD mode?

Yes

GO to A27.

No

If the PID 4WDCLST indicates OFFO-G, GO to A20 .

A20 CHECK CIRCUIT 976 (O) FOR SHORT TO POWER

GEM C241

Measure the voltage between GEM C241-15, circuit 976 (O), and ground.



Is any voltage indicated?

Yes

REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal operation.

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No

GO to A21.

A21 CHECK CIRCUIT 976 (O) FOR SHORT TO GROUND

A4WD Clutch Relay C293

Measure the resistance between A4WD clutch relay C293-D, circuit 976 (O), and ground.



Is the resistance greater than 10,000 ohms?

Yes

GO to A22.

No

REPAIR circuit 976 (O). CLEAR the DTCs. TEST the system for normal operation.

A22 CHECK CIRCUIT 976 (O) FOR OPEN

Measure the resistance between A4WD clutch relay C293-D, circuit 976 (O), and GEM C241-15, circuit 976 (O).



Is the resistance less than 5 ohms?

Yes

REPLACE the A4WD clutch relay. CLEAR the DTCs. TEST the system for normal operation.

No

REPAIR circuit 976 (O). CLEAR the DTCs. TEST the system for normal operation.

A23 MONITOR THE A4WD CLUTCH RELAY PID 4WDCLST

Monitor the PID 4WDCLST.

Rotate the mode switch between 2H and A4WD modes.



Does the PID 4WDCLST indicate ON--- when in the A4WD mode and is the A4WD lamp not flashing?

Yes

GO to A24.

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No

GO to A2 and verify all other DTCs are repaired.

A24 MONITOR THE PID 4WDCLST — REAR WHEELS BREAKING TRACTION

Monitor the PID 4WDCLST.

Verify the vehicle is in A4WD mode.

Position the rear wheels on a loose or slippery surface. Accelerate briefly to get the rear wheels to break traction.



Does the A4WD lamp begin to flash and the PID 4WDCLST indicate OFF?

Yes

GO to A25.

No

CHECK transfer case assembly C201 for intermittent short.

A25 MONITOR THE PID 4WDCLST FOR ON--- RESPONSE

GEM C241

Place the mode switch in the A4WD position.

Monitor the PID 4WDCLST.



Does the PID 4WDCLST indicate OFFO-G?

Yes

GO to A26.

No

If the PID 4WDCLST indicates ON---, REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST

the system for normal operation.

A26 CHECK CIRCUIT 976 (O) FOR SHORT TO POWER

A4WD Clutch Relay C293

Measure the voltage between A4WD clutch relay C293-D, circuit 976 (O), and ground.

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

Is any voltage indicated?

Yes

REPAIR circuit 976 (O). CLEAR the DTCs. TEST the system for normal operation.

No

REPLACE the A4WD clutch relay. CLEAR the DTCs. TEST the system for normal operation.

A27 CHECK THE A4WD OUTPUT

Transfer Case Assembly C201

NOTE: The CLCH SOL active command is located in the Shift Clutch Control active command menu.

Set the active command CLCH SOL to ENERGIZED.

Measure the voltage between transfer case assembly C201-16, circuit 779 (BR), and ground.



Is the voltage less than 5 volts when the active command is set to 0% and greater than 10 volts when

set to 100%?

Yes

REPAIR the transfer case clutch; REFER to Section 308-07B. CLEAR the DTCs. TEST the system for normal

operation.

No

GO to A28.

A28 CHECK CIRCUIT 779 (BR) FOR OPEN

A4WD Clutch Relay C293

Measure the resistance between A4WD clutch relay C293-B, circuit 779 (BR), and transfer case assembly C201-

16, circuit 779 (BR).



Is resistance less than 5 ohms?

Yes

GO to A29.

No

REPAIR circuit 779 (BR). CLEAR the DTCs. TEST the system for normal operation.

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A29 CHECK CIRCUIT 779 (BR) FOR SHORT TO GROUND

Measure the resistance between transfer case assembly C201-16, circuit 779 (BR), and ground.



Is the resistance greater than 10,000 ohms?

Yes

GO to A30.

No

REPAIR circuit 779 (BR). CLEAR the DTCs. TEST the system for normal operation.

A30 CHECK CIRCUIT 779 (BR) FOR SHORT TO POWER

Measure the voltage between transfer case assembly C201-16, circuit 779 (BR), and ground.



Is any voltage indicated?

Yes

REPAIR circuit 779 (BR). CLEAR the DTCs. TEST the system for normal operation.

No

GO to A31.

A31 CHECK A4WD CLUTCH RELAY CIRCUIT 57 (BK) FOR OPEN

Measure the resistance between A4WD clutch relay C293-C, circuit 57 (BK), and ground.



Is the resistance less than 5 ohms?

Yes

GO to A32.

No

REPAIR circuit 57 (BK). CLEAR the DTCs. TEST the system for normal operation.

A32 CHECK THE VOLTAGE TO THE A4WD CLUTCH RELAY — CIRCUIT 704 (DG/LG)

Measure the voltage between A4WD clutch relay C293-A, circuit 704 (DG/LG), and ground.

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PINPOINT TEST B: THE VEHICLE DOES NOT SHIFT BETWEEN 2WD/A4WD AND 4WD MODES PROPERLY

NOTE: Complete the entire pinpoint test related to the symptom before replacing the GEM.



Is the voltage greater than 10 volts?

Yes

REPLACE the A4WD clutch relay. CLEAR the DTCs. TEST the system for normal operation.

No

REPAIR circuit 704 (DG/LG). CLEAR the DTCs. TEST the system for normal operation.

CONDITIONS DETAILS/RESULTS/ACTIONS

B1 CHECK THE IGNITION STATES — MONITOR THE PID IGN_GEM

NGS

Monitor the PID IGN_GEM while turning the ignition switch through the START, RUN, OFF, and ACC positions.



Do the PID values agree with the ignition switch positions?

Yes

GO to B2.

No

REPAIR the ignition circuit (RUN/ACC: circuit 297 [BK/LG], RUN: circuit 687 [GY/Y], or START: circuit 32 [R/LB])

in question. CLEAR the DTCs. TEST the system for normal operation.

B2 RETRIEVE THE DIAGNOSTIC TROUBLE CODES (DTCS)

Retrieve Continuous DTCs

Clear Continuous DTCs

Retrieve On-Demand DTCs



Are any DTCs recorded?

Yes

If DTC B1342, REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal

operation.

If DTC P0500, GO to Pinpoint Test C.

If DTC P1483, GO to Pinpoint Test C.

If DTC P1485, GO to Pinpoint Test C.

If DTC P1804, REFER to Section 413-01.

If DTC P1806, REFER to Section 413-01.

If DTC P1808, REFER to Section 413-01.

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If DTC P1810, REFER to Section 413-01.

If DTC P1812, GO to B6 or Pinpoint Test C.

If DTC P1815, GO to B6 or Pinpoint Test C.

If DTC P1820, GO to B17 .

If DTC P1822, GO to B17 .

If DTC P1824, GO to Pinpoint Test A.

If DTC P1826, GO to Pinpoint Test A.

If DTC P1828, GO to B17 .

If DTC P1830, GO to B17 .

If DTC P1832, GO to Pinpoint Test D.

If DTC P1834, GO to Pinpoint Test D.

If DTC P1836, GO to Pinpoint Test A.

If DTC P1837, GO to Pinpoint Test A.

If DTC P1846, GO to B34 .

If DTC P1850, GO to B34 .

If DTC P1854, GO to B34 .

If DTC P1858, GO to B34 .

If DTC P1868, REFER to Section 413-01.

If DTC P1869, REFER to Section 413-01.

If DTC P1874, GO to Pinpoint Test A.

If DTC P1876, GO to Pinpoint Test D.

If DTC P1877, GO to Pinpoint Test D.

If DTC P1886, GO to Pinpoint Test A.

If DTC P1891, GO to B34 or Pinpoint Test C.

If DTC C1107, GO to Pinpoint Test A.

No

GO to B3.

B3 CHECK THE A4WD INDICATOR

NOTE: The A4WD LAMP active command is located in the 4WD Indicators active command menu.

Toggle the active command A4WD LAMP on, then off. The A4WD indicator should illuminate, then go off.



Does the indicator operate correctly?

Yes

GO to B4.

No

GO to Section 413-01.

B4 CHECK THE 4H INDICATOR

NOTE: The 4WD MODE L active command is located in the 4WD Indicators active command menu.

Toggle the active command 4WD MODE L on, and off. The 4x4 indicator should illuminate, then go off.



Does the indicator operate correctly?

Yes

GO to B5.

No

REFER to Section 413-01.

B5 CHECK THE 4L INDICATOR

NOTE: The LOW LAMP active command is located in the 4-Wheel Electronic Shift active command menu.

Toggle the active command LOW LAMP on and off. The 4x4 LOW indicator should illuminate, then go off.



Does the indicator operate correctly?

Yes

GO to B6.

No

REFER to Section 413-01.

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B6 MONITOR THE MODE SWITCH PID 4WDSGEM

Monitor the PID 4WDSGEM.

Rotate the mode switch through the 2H, A4WD, 4H, and 4L positions.



Does the PID 4WDSGEM agree with the A4WD switch positions?

Yes

GO to B13.

No

GO to B7.

B7 CHECK THE MODE SWITCH

Mode Switch C230

Rotate the mode switch to the 2H, A4WD, 4H, and 4L positions.

Measure the resistance between mode switch terminals 2 and 3 while rotating the mode switch through all switch

positions; refer to the following chart.

Switch Position Resistance Range

2H 3705-4095 ohms

A4WD 1425-1575 ohms

4H 646-714 ohms

4L 228-252 ohms



Are the resistances within specification?

Yes

GO to B8.

No

REPLACE the mode switch. CLEAR the DTCs. TEST the system for normal operation.

B8 CHECK CIRCUIT 780 (DB) FOR OPEN

GEM C241

Measure the resistance between mode switch C230-3, circuit 780 (DB), and GEM C241-8, circuit 780 (DB).

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