4WD Issues?

2012 FORD RANGER
130,000 MILES • 2.2L • 4 CYL • TURBO • 4WD • MANUAL
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STUART-RANGER
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I was hoping somebody could help, I have the truck listed above and whenever I've been driving on the motorway and then pull off on the slip road, as I'm slowing down, it will momentarily lose drive and then switch itself into 4WD low range. I have to then pull over and actually get it to engage 4WD low range to get it to switch back into 2WD High. It can then take a few goes, going a few feet, back and forward and restarting the truck to actually engage it back into 2WD. I've noticed that whilst I'm driving, the green 4WD symbol will occasionally flash.
The question is, would this be a problem with the actuator or the transfer box itself, and is there any way of disabling the 4WD system completely until I can diagnose and repair the fault, ie removing the fuse from the fuse box under the bonnet, so it doesn't engage at all, for the time being, as I need to use it to get to work to actually afford to fix it...!
Also, when i brought it, it had no service history so I'm not sure when any of the axle, transfer case or gearbox oil was actually changed.
Any help would be greatly received, and I will reply to ASAP.
TIA, Stuart
Jan 12, 2023 at 10:22 AM
Repair Safety Notice: This information is for general instructional purposes only. Vehicle repair can be dangerous. Verify all information, follow manufacturer service procedures, use proper tools and safety equipment, and consult a qualified repair shop when needed.
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STRAILER
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I would service the transfer case with new fluid and replace the transfer case control actuator. Here is a video to give you an idea of what you are in for when servicing the unit and I have added instructions for your truck in the images below for the service and actuator change.

https://youtu.be/jywt228y8UM

Fluid Types

Ford Part Name

- Motorcraft Transfer Case Fluid

Ford Part Number

- XL-12
Capacities

Transfer Case .................... 2.5 pt (1.2 L)

Check out the images (below). Let us know what happens and please upload pictures or videos of the problem.
Jan 13, 2023 at 10:09 AM
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STUART-RANGER
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Thank you ever so much for this Ken, I will give it a go, document it whilst I do and let you know how I get on.
Jan 13, 2023 at 10:32 AM
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STRAILER
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Thank you, it should fix it.
Jan 14, 2023 at 4:51 PM
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STUART-RANGER
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I drove the truck to work Monday morning, and just round the corner from work, the 4WD engaged and I couldn't get it to disengage. I got it to the car park, had a look at the actuator and it's been replaced before but rather than unplug the old unit, they've cut the wires and used connectors to rewire the replacement in. I still couldn't get it to disengage 4WD, no lights was on the dash to say it was in 4WD but the diffs was locked in, turns out my mum has AA breakdown, so I called them out, they sent a fitter, and he found one of the connectors was corroded, replaced it and now it switches between 2H, 4H & 4L again no problems. So, I shall be cutting all those connectors out and properly wiring somebody else's poor job they've done previously, and it'll get a good, complete service too.
Jan 18, 2023 at 12:21 PM
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STRAILER
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Nice work finding the problem, poor wiring causes many issues.

here is the wiring diagram and a guide to help with the repair:

https://www.2carpros.com/articles/how-to-check-wiring

Check out the images (below). Please let us know if you need anything else to get the problem fixed.

Jan 19, 2023 at 2:23 PM