• 1998 F-150/250 Workshop Manual Page 1 of 74 SECTION 308-07A: Transfer Case — General Information 1998 F-150/250 Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: Transfer Case—ESOF Refer to Wiring Diagrams Cell 34, Electric Shift Control for schematic and connector information. Refer to Wiring Diagrams Cell 20, Starting System for schematic and connector information. • 1998 F-150/250 Workshop Manual Page 2 of 74 Mode Switch Position Resistance (Ohms) 2-Wheel Drive 4100-3700 4WD HIGH 1050-1150 4WD LOW 380-340 Table 2 — Transfer Case Shift Relays Outputs HI-to-LO LO-to-HI Mode GROUND BATTERY 4 HIGH to 4 LOW BATTERY GROUND 4 LOW to 4 HIGH GROUND GROUND Brake Motor. • 1998 F-150/250 Workshop Manual Page 3 of 74 GEM Diagnostic Trouble Code (DTC) Index Description Caused By Action B1302 Accessory Delay Relay Coil Open or Short to Ground (Only REFER to Section 501-11. Set if Battery Saver Relay Has No Faults) B1304 Accessory Delay Relay Coil Short to Power REFER to Section. 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CarGurus analyzes over 6 million cars daily. • 1998 F-150/250 Workshop Manual Page 4 of 74 P1810 4-Wheel Drive LO Indicator Short to Power GO to Pinpoint Test P1812 4-Wheel Drive Mode Select Switch Open or Short to Power GO to Symptom Chart. P1815 4-Wheel Drive Mode Select Switch Circuit Short to Ground GO to Symptom Chart. • 1998 F-150/250 Workshop Manual Page 5 of 74 PARK_SW Headlamp Control Input Switch ON, OFF PLATE_A Transfer Case Contact Plate Switch A OPEN, CLOSED PLATE_B Transfer Case Contact Plate Switch B OPEN, CLOSED PLATE_C Transfer Case Contact Plate Switch C OPEN, CLOSED PLATE_D Transfer Case Contact Plate Switch D OPEN, CLOSED. • 1998 F-150/250 Workshop Manual Page 6 of 74 Transfer case mechanism. Digital transmission range (TR) sensor. The Front Axle Is Not Engaging Properly (Transfer Case Motor Movement OK) 4x4 solenoid. GO to Pinpoint 4x2 solenoid. Test Vacuum motor. Vacuum lines. • 1998 F-150/250 Workshop Manual Page 7 of 74 REPLACE the fuse(s). CLEAR the DTCs. TEST the system for normal operation. If the fuse(s) fail again, CHECK for a short to ground. REPAIR as necessary. A3 CHECK CIRCUIT 1052 (T/BK) FOR VOLTAGE Fuse Junction Panel C243 Measure the voltage between fuse junction panel C243-11, circuit 1052 (T/BK), and ground. • 1998 F-150/250 Workshop Manual Page 8 of 74 If DTC B1342, REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal operation. If DTC P1804, GO to Pinpoint Test If DTC P1806, GO to Pinpoint Test If DTC P1808, GO to Pinpoint Test If DTC P1810, GO to. • 1998 F-150/250 Workshop Manual Page 9 of 74 Monitor the GEM PID 4WDSGEM. Place the mode switch in the 2H position. Does the GEM PID indicate 2WD? A9 CHECK THE 4WD MODE SWITCH — MONITOR THE GEM PID 4WDSGEM (4H) Place the mode switch in the 4H position. • 1998 F-150/250 Workshop Manual Page 10 of 74 Mode Switch C230 Place the mode switch in the 2H position. Measure the resistance between the mode switch terminal 2 and terminal 3. Is the resistance between 3700 and 4100 ohms? REPLACE the mode switch. • 1998 F-150/250 Workshop Manual Page 11 of 74 REPLACE the mode switch; REFER to Section 308-07B. CLEAR the DTCs. TEST the system for normal operation. A13 CHECK THE 4WD MODE SWITCH — 4L Place the mode switch in the 4L position. Measure the resistance between the mode switch terminals 2 and 3. • 1998 F-150/250 Workshop Manual Page 12 of 74 Is the resistance greater than 10,000 ohms? REPAIR circuit 780 (DB). CLEAR the DTCs. TEST the system for normal operation. A16 CHECK CIRCUIT 780 (DB) FOR SHORT TO POWER Measure the voltage between GEM C241-8, circuit 780 (DB), and ground. • 1998 F-150/250 Workshop Manual Page 13 of 74 REPLACE circuit 682 (DB). Cab To Canada 1998 Download YoutubeCLEAR the DTCs. TEST the system for normal operation. A18 CHECK CIRCUIT 682 (DB) FOR SHORT TO GROUND Multi-Function Switch C259 Measure the resistance between mode switch C230-2, circuit 682 (DB), and ground. Is the resistance greater than 10,000 ohms? • 1998 F-150/250 Workshop Manual Page 14 of 74 Is the axle disconnect working properly? EXIT the active command mode; GO to GO to Pinpoint Test A21 CHECK THE FRONT DRIVESHAFT ENGAGEMENT Place the mode switch in the 4H position. Verify the front and rear driveshafts both spin. Is the transfer case locking the front driveshaft to the rear driveshaft? • 1998 F-150/250 Workshop Manual Page 15 of 74 A24 CHECK THE TRANSFER CASE SHIFT RELAYS COIL ACTIVATION — MONITOR THE GEM PIDS MTR_CCW AND MTR_CW Monitor the GEM PIDs MTR_CCW and MTR_CW while triggering the GEM active command CW/CCW ON. Do the GEM PIDs MTR_CCW and MTR_CW indicate ON---? • 1998 F-150/250 Workshop Manual Page 16 of 74 Is the resistance less than 5 ohms? REPAIR circuit 781 (O/LB). CLEAR the DTCs. TEST the system for normal operation. A28 CHECK CIRCUIT 782 (BR/W) FOR OPEN Measure the resistance between transfer case shift relays C221-8, circuit 782 (BR/W), and GEM C241-16, circuit 782 (BR/W). • 1998 F-150/250 Workshop Manual Page 17 of 74 GEM C241 Measure the voltage between transfer case shift relays C221-8, circuit 782 (BR/W), and ground. Is any voltage indicated? REPAIR circuit 782 (BR/W). CLEAR the DTCs. TEST the system for normal operation. • 1998 F-150/250 Workshop Manual Page 18 of 74 A33 CHECK THE VOLTAGE TO THE ELECTRIC SHIFT MOTOR — MOTOR ON Transfer Case Assembly C201 Trigger the GEM active command CW/CCW to ON. Measure the voltage between transfer case assembly C201-14, circuit 778 (O), and ground; and between transfer case assembly C201-15, circuit 777 (Y), and ground. • 1998 F-150/250 Workshop Manual Page 19 of 74 Trigger the GEM active command CW/CCW to OFF. Measure the voltage between transfer case assembly C201-14, circuit 778 (O), and ground; and between transfer case assembly C201-15, circuit 777 (Y), and ground. Are the voltages greater than 10 volts? • 1998 F-150/250 Workshop Manual Page 20 of 74 Are the resistances less than 5 ohms? RECONNECT the transfer case assembly. GO to GO to A40. A38 CHECK CIRCUIT 777 (Y) FOR OPEN Measure the resistance between transfer case shift relays C221-7, circuit 777 (Y), and transfer case assembly C201-15, circuit 777 (Y). • 1998 F-150/250 Workshop Manual Page 21 of 74 Measure the resistance between transfer case shift relays C221-1, circuit 57 (BK), and ground. Is the resistance less than 5 ohms? REPLACE the transfer case shift relays. CLEAR the DTCs. TEST the system for normal operation. • 1998 F-150/250 Workshop Manual Page 22 of 74 REPAIR the transfer case (7A195) or shift motor assembly; REFER to Section 308-07B. CLEAR the DTCs. TEST the system for normal operation. A42 MONITOR THE GEM PID PLATE_A FOR OPEN Transfer Case Assembly C201 Trigger the GEM active command PLATE POWER to ON. • 1998 F-150/250 Workshop Manual Page 23 of 74 GEM C241 Measure the resistance between transfer case assembly C201-5, circuit 771 (P/Y), and ground. Is the resistance greater than 10,000 ohms? REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal operation. • 1998 F-150/250 Workshop Manual Page 24 of 74 Is any voltage indicated? REPAIR circuit 771 (P/Y). CLEAR the DTCs. CYCLE the ignition OFF then ON. TEST the system for normal operation. A47 CHECK CIRCUIT 762 (Y/W) FOR SHORT TO POWER Measure the voltage between GEM C241-12, circuit 762 (Y/W), and ground. • 1998 F-150/250 Workshop Manual Page 25 of 74 GO to A51. A50 CHECK THE CIRCUIT 770 (W) TO THE CONTACT PLATE SWITCH B — MONITOR THE GEM PID PLATE_B Connect a jumper wire between transfer case assembly C201-10, circuit 762 (Y/W), and C201-1, circuit 770 (W). • 1998 F-150/250 Workshop Manual Page 26 of 74 Is the resistance less than 5 ohms?
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