96 4x4 Problem

Angus0914 · September 8, 2008

I'm new to this so this might seem like a silly question. I have a 96 1500 that will not go into 4X4. There is no voltage at either connector that is on the front axle. From my looking the form here it looks to be one of two things. Either the wiring or the tranfercase switch. My question is where is the transfercase switch and what voltages should I see when I find it? Thanks for any help. It is a NV241c transfercase with a 272 ratio.

L29er · September 8, 2008

Check your ball switch on top if the t-case, common thing to fail aswell... remove plug (3 wire style) remove switch from t-case ( i think its 1 1/8"???? anyways get it out and see if the ball on the end is firmly stuck out if you can push the ball in and there is no spring pressure to push it out replace it, it it appears fine one wire is ground refrence with a multi-meter, another will have 12v with key on and another with have a 5v reference (for computer refrence)

Ball switch is located directly above the shift arm, what ever you wanna call it, it will have a three wire connector...

THIS IS IF ITS A MANUAL SHIFT UNIT!! autos are abit different

Angus0914 · September 8, 2008

Ok I checked the ball switch on the transfer case and there is good spring pressure there. There are two connectors on the transfer case one right by the shift arm which has a brown and lightblue wires on it that is connected to the ball switch. With the key off both wires have a ground on them. With the key on the brown wire has 12v on it and the lightblue still has a ground on it. The other connector at the back of the transfercase has a green and purple wire on it. With the key off there is a ground on the green and the purple is not grounded. With the key on the green wire still has a ground on it and the purple wire has no voltage on it. Does it make a difference if the truck is started or not? I could not find a connector with three wires on it and I also could not find the 5v you talked about. I'm kind of at a loss because I don't know what I should be seeing. If there is anyone out there that could explain it that would be really help. Thanks

L29er · September 9, 2008

SORRY THE THREE WIRES IS FOR AN AUTO T-CASE. K the pruple and green wires is your speed sensor so you can ignore that one, alright so thing to do is with ball switch and front diff actuator removed from housing turn key on and depress ball switch if actuator moves out this is proper operation...anyways if the above doesn`t actuate the actuator...you could try to jumper the switch at the pigtail to eliminate a bad ball switch. if not, there isnt voltage out front so inpect for an open in the wiring from the switch up to the actuator, the most common places for problems are places were there are tie downs and bends in the loom.. hope this helps, (:

Angus0914 · September 11, 2008

If I have to replace the wiring can I just splice into the wires at the transfer case and run new ones to the front? Is it 12v to make the front lock in? Thanks

L29er · September 12, 2008

YUP 12V, so does jumping 12v up ther make her work? do that before you re-wire it...just to confirm (:

Angus0914 · September 15, 2008

Thankyou very much Stumpuller. It turned out to be a wire was grounding out by the connector on the front. It was in the factory clip there and the clip was pinching the wire. When I took it out of the clip I could see some copper strands. Once I took it out of there and taped it up it works fine. Thanks again. Now I'm working on a front brake that is the piston is seized. Only have a few more weeks to be for moose season. I should have her all ready to go by then.

L29er · September 15, 2008

GLAD TO HEAR! about the 4x4 thing anyways, don`t be surprised if you have to replace both calipers, sometimes it will end up pulling towards the side with the new caliper cause it works better than the old original one on the other side... but try it first hate to throw parts at it!

Angus0914 · September 16, 2008

Well got the brakes done last night and everything is good there so far but when I put in 4X4 it did not go in the first time. The second time it did go in and worked fine. When I tried it again it would not go in again. When I tested on Sunday it worked 8 times in a row in 4 high and 4 low. What are your thoughts I did not get the wiring trouble or can a acuwaiter do this intermittent? Thanks

L29er · September 16, 2008

hmm you may want to ohm the wires from the ball switch up to the actuator could be some resistance or another rubbed spot, otherwise the ball switch is probly the cheaper thing to try and replace first. should be less than .5 ohms. although sometimes in my truck i have to move a little bit just to get the collar in the front diff engaged...its just normal

Angus0914 · October 5, 2008

Well I'm all done the front brakes that was not to bad. The darn 4X4 is still working on and off. I checked the restance of both wires while the 4x4 was working and it was about 1.5 ohms. I'm thinking that it is anouther wire. I traced from both directions but can't see behide the engine. I think I feel a connector there. Is this where the 12v comes from? I'm thinking that I'm just going to replace the wire from the actuator to a toggle switch and use a spare fuse spot or an inline fuse. Will this work and what size of fuse would I have to use? Thanks

L29er · October 6, 2008

the 4wd fuse in the truck is a 20 amp fuse so don`t use anything bigger than that. i`d probly just run another wire from the ball switch up to the actuator but thats up to you...