Ok so I have an 02 FX4, 5 speed twin stick, and I can shift into 4wd no problem and it engages. I can shift into 4wd low no problem and it engages. I can shift out of either and back into 2wd no problem....

SOOOO..... here's my problem: The damn 4wd and 4low lights on the dash refuse to work correctly. Sometimes 4wd light is stuck on (no matter if I'm in 2wd, 4wd, or 4low), sometimes 4low light is stuck on, sometime nothing lights, sometimes they both light, and even furthermore, but rarely, the lights work normal.

Again, transmission shifts and runs 100% correctly (even after my amateur slave cylinder replacement).

On a side note, I will say this. That transmission, or at least the shifter assembly, has DEFINITELY been taken apart before I owned the truck. The 4h/l shifter has 2 bolts holding it to the shift lever that goes into the transmission. The bottom of those two bolts has the threads stripped and the bolt hole is somehow too large. I've pulled them out and compared them... they are the same size bolt. Because of this little mishap, the shifter sometime feels as if it wants to "snap in half". It's a weird feeling but at least I know what's causing it.

Now... WHY DO MY DASH LIGHTS ACT UP LIKE THAT???

Thanks in advance.

Bump, anyone??

Dash lights are triggered by a sensor in the tcase. I'm betting its bad.

Dash lights are triggered by a sensor in the tcase. I'm betting its bad.


The tcase or the sensor?

Is the sensor hard to get to?

The sensor. Im not sure how hard it is to get to. I dont have the manual case. I cant see it being difficult.

Yeah I actually got down and looked under there in this 25 degree, sleet, snow, and ice weather we are having. Let me tell you how much of a mistake that was...

Anyway, I think I found this sensor. It looks to be on the very top of the tcase, and quite difficult to stick my hand in there. I can just imagine getting a tool in there to remove it...

Tomorrow is another day so I will try again.

Yep, the sensor is at the top of the case on the drivers side. Look at the bright side, at least you don't have the electric shift garbage!

Yep, the sensor is at the top of the case on the drivers side. Look at the bright side, at least you don't have the electric shift garbage!


HA! Yeah my girlfriends truck has that servo motor madness thing going on. Her dad (who happens to be a mechanic ((yeah we've never heard that one before :tongue ))) replaced that motor to the tune of $400 before she inherited the truck.

Ok so now there is a need to reply to my own thread. I have found the sensor/switch on the tcase by following the wiring harness going to it. It feels like a large spark plug with a connector on it. The issue is I cannot remove it because, well, I don't have the right tool to do it. None of my deep well sockets were large enough and I can't get a wrench in there, so...... what damn size socket takes that thing off? It would be different if I could SEE what I'm doing, but christ that sensor is in a bad spot. For now, I have left the wiring harness disconnected.

I seriously hope I don't have to lower the tcase to get clearance to remove that thing....

I love how I always have to bump my own threads to get the answer I need.

What is the name of the sensor in question? I called a few dealerships today and they don't even know what I'm talking about...

To refresh everyone's memory (yeah the whole 3 people that MIGHT read this)... I need the sensor/switch that sits on the top of the transfer case in an 02 FX4, 5 speed, MECHANICAL range control.

Help?

Best i can come up with is genuine 4x4, 4x4 mode switch.

My ford service manual for 02 doesnt include the repair of it but does describe how to adjust the linkage.

Not much help I know.

Hmm.... well seeing as how today is Xmas, the dealership won't be open. I'll go there tomorrow and see if they can shed some light on this. If they happen to identify the part... I'll come back here and post the name of it so other mechanical shift 4x4'ers won't go through the same crap I am.

Thanks anyway, Blhde.