Always in AWD

Tiny
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The yellow wire comes from the module in the truck. Diagram attached.

Roy
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Thursday, February 14th, 2019 AT 2:28 PM
Tiny
JIM2CARPROS
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Any other ideas? We still haven’t solved the issue yet. Isn’t this fun?
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Sunday, February 17th, 2019 AT 5:32 AM
Tiny
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You were going to check the yellow wire as per the last conversation?

Roy
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Sunday, February 17th, 2019 AT 1:16 PM
Tiny
JIM2CARPROS
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Sorry for the slow response. Been doing a lot of reading on this topic, that is to say, as much as I can find. First of all the wire going to my transfer case housing is white not yellow. Interesting first observation but not sure what impact that has on our diagnosis. Second, the function of that clutch coil is to spin up that side of the transition to speed when shifting into 4WD while driving and my personal thought is that this really has no impact on the problem I'm having which I believe is a shift fork not disengaging from 4AWD back to 2WD. So as not to blow up the transfer case, now on the car, I did not apply voltage (worried that 12 volts direct from the battery may not be the correct voltage application of electrical power) to that clutch/coil pack in the transfer case.

Starting reading about earlier model of transfer cases and apparently 1999 (not sure of the scope of this style of transfer case set up) had a vacuum trigger to pull the shift fork back out of the 4AWD engaged position to the 2WD position. There is a large hose on top of the transfer case that I did not trace when I put the new (used) transfer case in. I assumed it was for moisture evaporation the way the IWE actuators have a small 1/8"ish version of hose that does this. Anyway, in the older models, the 4AWD to 2WD motion of the shift fork was vacuum triggered (I read that if there is a leak, the amount of vacuum applied would not overcome the force needed to pull the shift for out of the 4AWD position into the 2WD position) come to find out and thought I would trace this with some help on the top side to see if it was vacuum hose and evaluate that possible diagnosis. I reconfirmed, in my reading that the shift motor only have three positions of alignment, 2H/4AWD, (however it is labeled 2H) 4H and 4L.

Do you know if that lonely, single 3/8"ish port on top of the transfer case is evaporation or vacuum? We are running out of options. It is becoming a matter of pride and drive. I almost gave up last week.

Jim
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Monday, February 25th, 2019 AT 5:50 AM
Tiny
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Okay, Did you get this information?

Roy

Transfer Case-Automatic Four-Wheel Drive (A4WD)

Features and Operation
The Automatic Four-Wheel Drive (A4WD) transfer case uses an electronic shift 4x4 system that allows the operator to choose between four different operational modes. The operator can switch between 2WD, A4WD and 4WD HIGH modes at any speed. However, to engage or disengage LOW Range, the 4WD Control Module requires that the vehicle speed is less than 5 km/h (3 mph), the brake is applied, and the transmission is in NEUTRAL.
In A4WD, the 4WD Control Module varies the torque split between front and rear drivelines by controlling the transfer case clutch. Under most conditions, the 4WD Control Module activates the transfer case clutch at a minimum duty cycle (percentage of time the clutch is turned on) which allows for a slight speed difference between the front and rear drivelines which normally occurs when negotiating a corner on dry pavement. When the rear wheels are overpowered, the 4WD Control Module detects this slip condition, and the duty cycle to the transfer case clutch is increased until the speed difference between front and rear drivelines is reduced. In this manner, the 4WD Control Module can redirect engine torque to the front wheels when the rear wheels lose traction yet still allow operation in the A4WD mode on dry pavement.
When the ABS system is active, the 4WD Control Module will default to a minimum duty cycle for the transfer case clutch.
Feature Inputs:
Shift range selector switch.
ABS active input (battery voltage when ABS is active, grounded when inactive).
Contact plate position inputs A, B. C, D grounded when closed, open circuit when open.

Feature Outputs:
Solid state clutch relay (pulse width modulated signal: grounded when relay is on, battery potential when relay is off).

Shifting Between 2WD, A4WD and 4WD HIGH
The operator can switch between 2WD, A4WD and 4WD HIGH mode at any speed.

Shifting Into/Out of LOW RANGE
When shifting into or out of LOW RANGE, the 4WD control module requires that the vehicle speed is less than 5 km/in (3 mph), the brake is applied, and the transmission is in NEUTRAL.
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Monday, February 25th, 2019 AT 12:36 PM
Tiny
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I got it and have read this information a few times. Not sure what it is telling me? Should I be looking for an ABS active input fuse?
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Monday, February 25th, 2019 AT 12:56 PM
Tiny
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I read it as well. If it was the fuse, the ABS light would be on.

The hose is a vent line to atmosphere.

Roy
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Monday, February 25th, 2019 AT 1:17 PM
Tiny
JIM2CARPROS
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Here is my plan but not sure how it can help: I am going to go through all fuses and relays in the passenger kick panel fuse box on Sunday if time permits and test every one for continuity.

My concern is, that with only one wire going into the transfer case (powering the coil/clutch), and no vacuum lines, how can this be an electrical problem? The TCSM is in the correct 2H/4AWD position with only 4H and 4L options both of which would be wrong. I would give my left pinky to figure this out.
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Wednesday, February 27th, 2019 AT 6:10 AM
Tiny
KEN L
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Here is the complete 4wd wiring diagrams with a guide to help you test the connection:

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

Check out the diagrams (below). Please let us know what you find. We are interested to see what it is.
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Friday, March 1st, 2019 AT 2:17 PM
Tiny
JIM2CARPROS
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Sorry, I have to the splined gear on the front axle side gets pulled into a neutral position when the white wire to the magnetic clutch coil receives power. That's the prob Bob. Now I have to find out why it is not getting power. Is there a simple relay you know about that I can locate and change? I don't think it is the TCCM because I tried three others and they didn't help. Any ideas?
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Monday, March 25th, 2019 AT 6:31 PM
Tiny
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I sent you the same diagram Ken sent you as well. There is no simple relay in the circuit.

Can you get a scan tool that can do bi-directional testing and see if you can command this thing into two wheel?

Roy
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Monday, March 25th, 2019 AT 6:53 PM
Tiny
JIM2CARPROS
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Not sure where I could get access to that tool.
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Monday, March 25th, 2019 AT 6:56 PM
Tiny
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It is a full blown scan tool, not a code reader.

It may be helpful to take it to a shop and ask them if they can check it for you.

Roy
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Monday, March 25th, 2019 AT 6:59 PM

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