4WD Issues - Opinions Wanted

[coder]

This all happened today while 4wheeling out in the desert.

Here are the symptoms:

1) When I unlocked the front axle (it physically unlocks) but the front locker light stayed solid and the rear locker light flashes like it won't unlock. If I turn off and turn back on the truck solid front locker light goes away.
2) The dash 4WD light come on in 2HI but goes completely off in 4LO/4HI (yet everything seems to physically work correctly)
3) I never get a serv4wd light

Any ideas, front axle locker actuator, transfer-case position sensor, other?

[Pit Slave]

Wow, two in a week! Sounds like the transfer case position sensor.

[RustyPW]

Wow, two in a week! Sounds like the transfer case position sensor.

Bingo! Winner!

coder, I thought you would know this, as many times this has come up.

[TwinStick]

It is in a bad spot i think. At least for us guys that live in the salt belts anyways.

[coder]

coder, I thought you would know this, as many times this has come up.

I had my suspicions but I always like to get input from the guys in the forum

[coder]

It is in a bad spot i think. At least for us guys that live in the salt belts anyways.

is it a pain to change?

[cruz]

is it a pain to change?

coder, doesn't look to be that hard.

[coder]

is it a pain to change?

coder, doesn't look to be that hard.

Where on the t-case is that is that, on top where the locker bypass plugs in?

[cruz]

This is all I could find, doesn't even say what #3 is, but it looks like the sensor to me...

[RustyPW]

is it a pain to change?

coder, doesn't look to be that hard.

Where on the t-case is that is that, on top where the locker bypass plugs in?

Yep, that's where the bypass plugs in.

[coder]

Got a new sensor (dealer had one must be a common replacement item) and a 1 1/2" deep socket to remove it. I'm going to replace it and clean-up and seal off the locker bypass plug with some silicone hopefully this will do the trick.

[coder]

The replacement is done everything works fine now. The old sensor did not push in smoothly like the new one it felt like it was binding so this must be a wear item mine had 118k miles on it. It was not real hard to do it took about 30 minutes.

[TwinStick]

So, it is on the top but is it on the front side or back side top ? Looks like the front side to me in that drawing ???

[Mule]

Anyone know what happens (gauge-/indicator-wise) when the sensor fails open?

Haven't really dug into the issue... 4WD light stays on. Used to go off in 4HI, now it's just on all the time.
Previous owner's solution: electrical tape over the light.

[RustyPW]

So, it is on the top but is it on the front side or back side top ? Looks like the front side to me in that drawing ???

Drivers side, above the transfer case linkage. Look for the wires going to the sensor. The drawing is looking at the front of the transfer case. On the left of it, is where iit goes into the tranny. The right side is the front driveshaft flange. #3 is the sensor. #2 is the linkage.

[RustyPW]

Anyone know what happens (gauge-/indicator-wise) when the sensor fails open?

Haven't really dug into the issue... 4WD light stays on. Used to go off in 4HI, now it's just on all the time.
Previous owner's solution: electrical tape over the light.

Sounds like you have the same issue.

[coder]

Anyone with a 4WD light that stays on needs to replace this switch they seem to go bad around 100k miles. Its a relatively inexpensive part retail price at the dealer is $77.95 they can be purchased online for about $60 + shipping.

Install tips; location is on top of the transfer case just behind where the front driveshaft connects, remove the small skid-plate just below the transfer case, unhook the transfer case shift linkage at the transfer case (pop it out of the rubber grommet) to improve access, use a 1-1/2" deep socket to unscrew the switch, the torque spec is 20 ft. lbs. or just snug when reinstalling.

Transfer Case Position Switch:
Mopar PN: 05083138AA

[jeep_boy02]

Mine went out at 75k, same symptoms

[TwinStick]

Sounds like a good part to have on hand or a spare of.

[Mule]

Yup.... nothin'. New one in and workin like a champ.

[Mr.Smith]

@ 3:30AM this morning, when I needed it of course...
4lo shows 4hi
Neutral shows 4lo
2wd shows 4hi
4hi shows 2wd
Sounds like TCPS to me, what do you think? Anyone else have a similar issue?

[RustyPW]

Yea, it's shot. Time for a new one.

[Mr.Smith]

Hahaha! Now to acquire one & a new seal as well...
What's this sensor?
http://www.quad4x4.com/cgi-bin/commerce ... &key=11011

[coder]

Hahaha! Now to acquire one & a new seal as well...
What's this sensor?
http://www.quad4x4.com/cgi-bin/commerce ... &key=11011

Not sure, but that's a different switch than I installed....

[Mr.Smith]

Yeah it was one that TwinStick posted along with a transfer case position switch...just trying to figure out where it went...???