Ford 6.0L Power Stroke Diesel :: 4x4 LOW Light Stays On / TC Not Shifting
Sep 19, 2016
2003 F250 6.0 ESOF - 4x4 and LOW lights on, TC not shifting
About the truck: 2003 F250 CCLB 6.0L 210k Miles
Heavy Duty Bulletproof Diesel Kit
Warn Front Manual Hubs (vac lines clamped/blocked)
Transfer Case Shift Motor/TCSM is off (I personally have not tested it and am still looking for what to test on it) or I will purchase a new one.
From seller: "What happened is, I accidently put it in 4x4 and when I turned the switch it would not go out. I had to limp it home slowly. When I got home I messed around with it, and could not get it to go back into 2x4. I removed the shift motor, and tested it. It tested ok. I shifted to back to 2x4 with a wrench and left it."
CURRENTLY the TCSM is off the transfer case and is in 2WD. Warn hubs are set to "FREE," seller also noted that this is how he has been driving it for quite sometime. TCSM is in 4x4 LOW, that is what I have to manually shift the transfer case to if I want to mount it up. I have been shifting it using a 14mm open end wrench and with the transmission in neutral. I have not tried turning the TCSM position manually.
Scanning using AE brings up different codes depending on transmission position and which scan is used:
P1812 4-Wheel Drive Mode Select Circuit Failure
P1819 Transmission Neutral Safety Switch Short Circuit To Ground
P1832 Transfer Case Differential Lock-Up Solenoid Circuit Failure
P1876 Transfer Case 2 Wheel Drive Solenoid Circuit Failure
P1865 Transfer Case Contact Plate Power Short to Ground
AE scanning for DTCs: P1832 and P1876
AE scanning using OnBoard System " SYSTEM SELF TEST" with transmission in PARK: P1812, P1832, P1876
AE scanning using OnBoard System " SYSTEM SELF TEST" with transmission in NEUTRAL: P1812, P1819, P1876
AE scanning with TCSM off: P1865, P1832, P1876
P1865 seems to be solved by simply installing the TCSM.
AE Live Data shows correct indicators for 4WD switch, showing corresponding drive mode in AE as the switch setting but nothing happens. No clunk/thud/movement. I have tried resetting the codes but the 4x4 and LOW lights both stay on. I tried it in park, neutral, engine off and engine on. I tried driving 5-10 mph to relieve any driveline wind up, I tried driving in reverse with front hubs free and locked, gave the same results in AE and no transfer case shifting.
Section 308-07A Four Wheel Drive Systems Pinpoint Test I
Found a thread with some fuses to check, I have checked fuses #19, 27, 31, 33, 34, 45 and 111 (with a multimeter for continuity),
Relays (first swapping the old ones, then trying new ones), I did the pinpoints from test I, and installed another GEM (same part number as mine but from a 2005 F-350)
Section 308-07A Four Wheel Drive Systems Pinpoint Test I led to my purchase of a used GEM, not knowing if it is good or bad, I have determined that I get the exact same codes for each AE Scan as the GEM that came with my truck.
I included a photo of my relay box, have any of you seen this type before? There is no other box in the engine bay with twin relays.
Air/Defrost switch works and routes air to switch setting. AC works, DEFROST works.
Could PVHS be causing a code from the manual hubs?
Could the MSS be causing a code even if it is showing correct in AE?
Should I try a new TCSM? Should I try turning the TCSM manually? How do I test, what do I test for on the TCSM?
I want to avoid taking this to the dealer if their own service manual and diagnosis is going to have the same results as my testing.
Where do I go from here?
Could PVHS be causing a code from the manual hubs?
Could the MSS be causing a code even if it is showing correct in AE?
Should I try a new TCSM? Should I try turning the TCSM manually? How do I test, what do I test for on the TCSM?
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