Ford F-150 - 1997-2003 :: 4x4 Will Engage But Only Disengage If Reset GEM


Jul 24, 2016

I recently bought a 1997 f150 4x4 with shift on the fly. I bought the truck from an old man who parked it outside his house. I love the truck, but the 4x4 has been finiky. I have done a ton of research and i have done a bunch of testing. The vacuum system is working correctly. I have tested the solenoids and the front axle actuator is working properly.

There is some kind of electrical issue. It might be the GEM (i really hope not), but it might be the shift on fly switch itself.

The 4x4 will engage, but when i turn the switch to 2h nothing seems to happen. Driving in reverse doesn't work. But sometimes it switch from 4h to 2h, just by turning the truck off and restarting it. If restarting doesn't work, then i have to pull the 5 fuse, let it sit, then put it back in. I read that this resets the GEM. (Number 5 fuse, middle row, 5th from the top).

Resetting the GEM usually does it, but not all the time. Sometimes it will still be in 4x4 again after resetting the gem. And then what is really weird, after driving it in 2h (after the gem reset) then turned it off and restarting it, it will go back into 4x4. All this happens with the switch set to 2h. So I have been having to reset the GEM, each time i restart it. (This was going on for a day or so.)

Any easy testing i can do? Do you think it could be the switch on the dash, or more likely to be the gem? I hope it isn't the gem. I don't want to have to pull a fuse each time to drive my truck.

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The A/C worked fine when I first purchased the car a few months ago. Shortly after my 800 mile trek from Oregon, back to home, the A/C started to only work intermittently. The compressor would engage, then disengage, repeat...It seemed like a bad idea to keep trying to use it in its sad state so I stopped using it altogether. As I said, I had the system emptied and recharged, but it still only works intermittently. It sort of follows a pattern where upon start up it works longer, and switches on and off at shorter intervals, until it doesn't engage at all.

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Passat (B6) :: 2007 - Parking Brake Won't Engage / Disengage?

owner of a 2007 Passat 2.0T wagon, 6 spd manual, 32k km's. (leased) I'm having repeated persistent parking brake failures (won't engage, or won't disengage).

-About two months ago the parking brake would not disengage, error message on the MFD, yellow warning light and warning tone. Called roadside, finally got it disengaged by removing one terminal from the battery. Took it straight to the dealership, they "fixed" it by resetting the computer.

- The next day I have auto hold engaged, parking brake did not disengage when I turned the car back on. Had to turn engine on/off several times before it disengaged.

- Took it to the dealership again, had to get a rental car over a weekend while they diagnosed the problem. This time they changed some wiring and replaced the parking brake button.

- Next day the parking brake engaged ok but wouldn't disengage. Same routine on/off/on/off to get it to disengage.

- Back to the dealership again, they decided to replace the brake control module but didnt have stock.

- Last week I took the car back in (4th trip for this issue), they replaced the module and said it was fixed. Next day my wife got stuck in a parking lot with the parking brake stuck on.

- Called the dealership last friday and asked them to come pick it up this time, as my wife and I are sick of the inconvenience of this issue. (we share the car, both work, and also have a child's daycare to schedule around)

The problem is intermittent but not difficult to cause a fault. Can be caused when engaging, disengaging, or when the PB kicks in from auto hold when turning the car off. I try not to use it, but sometimes is necessary (parking on hills etc).

The dealership doesnt seem to know the problem and are just throwing parts at it. What recourse do I have for repeated problems? The manual recommends using this parking brake EVERY time the car is parked, so I don't think it's too much to ask to have it working properly.

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Ford F-150 - 1997-2003 :: 4x4 Won't Engage When Cold

I've got a problem with my 4x4 not engaging. I've been ready and re-reading all the related posts and threads and am still confused. Here goes. Early in the fall I had no problem shifting in or out of 4wd. Then when it got well below freezing up here, it stopped working. I had it in a warm shop and all of a sudden it worked fine. After sitting outside again it wouldn't work.

When it was warm, I had no problem shifting in and out of 4x4, dash lights functioning as normal. As it got colder it only seemed to work if I really pulled quite hard on the stick and the 4Low indicator didn't work but 4Low was obviously engaged. Now after another day or two outside, nothing happens at all. When the diff does engage, shifting out of 4x4 is never a problem.

Transfer case seems fine as the front drive shaft turns when I shift into 4H and drive forward. After researching a bit, I crawled under and pulled the blue line off the actuator and had someone shift into 4H, I couldn't feel any vacuum so figured it must be the engage solenoid especially since, shifting out of 4x4 is never a problem.

My question now is, shouldn't the lights on the dash be on even if the solenoid isn't working? I am now starting to wonder if its the sensor switch on the transfer case but I don't see how freezing should affect the switch and would think I'd have issues shifting out of 4x4 as well as in. If I put it in 4X4 and test for current at the solenoid and it is there, can I assume that the switch is fine and the problem is in fact the solenoid?

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My current dealer says all they can do for it now is REPLACE THE WHOLE FREAKING CLUTCH assembly to the tune of $1,300. Clearly, I'm not doing this. As long as it works, I ain't replacin' the clutch, but, REALLY?

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Ford F-150 - 1997-2003 :: 1999 - Key Won't Engage Lock?

1999 F-150 Sport 4x4

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Looking for a diagram/picture of how it should look to get everything put back together so the key'll work again. Sucks unlocking passenger side and climbing over to open driver door.

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Just tried to engage my 4x4 today to see if it was working and nothing. It is the electronic shift on the fly. I started checking the vacuum hoses and found one that looked like a mouse chewed threw part of it and repaired that line. Still no 4x4. So...there are no lights coming on, no sound from the transfer case shift motor and no noise of any kind when cycling the shift ....

I pulled the connection apart at the shift motor to test for voltage with 2hi and truck running and no 12volt. I tested all the pins but not sure if i did it correctly. Also the shift motor itself is rusty on the outside casing. What pin to test for voltage?

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