I could use your input. I have a 1994 Ex Cab v-6 with ADD. My problem is that the transfer case won’t disengage low range. The ADD works fine. I just can’t get it out of low range! Physically the lever is smooth and shifts into H2 and H4 positions fine and the driveshaft disengages. Is it possible the #4 solenoid is faulty? The engine sets no codes and I can hear the solenoid engage/disengage when I apply battery voltage to its connector at the ECM. The resistance at the ECM connector for that solenoid is 10 ohms. FSM says it should be 11-15. I just bought the truck a few miles ago. I changed the tranny and tcase fluid as a matter of pm and then I tried the 4x4 out. It worked ok at first, for a few cycles, but then it locked in 4Land wouldn’t come out. I let it sit for a while, then it was ok. Now it is locked in and has been for several days! Does that sound like a solenoid or a more serious problem in the hydraulic control unit or tcase? The dealer wants $160 just for the solenoid. I don’t want to throw darts at the problem. Any help would be appreciated!

Jerrod L

 

i really don't think it's because of any solenoids. sounds like something is binding up bad in the t-case

 

Truck really wasn't an off-road truck, so I am hoping for something easier. Ever heard of one getting stuck in 4Lo before? Like I said, the 4x4 will disengage, but not the Lo range? Thanks for your input.

 

I'm wondering if something broke internally on your tranfer case...Like maybe the shift lever or something. Why don't you get in touch with Marlin...Just do a search on Marlin Crawler. He specializes in Toy transmissions and transfer cases. I'll bet he can tell you what happened and how to fix it.

 

I think gwhayduke is right about something breaking inside. If I remember correctly the shifter controls two rails: one for the 4 wheel drive and one for the low range. It sounds like the shifter link for the low range isn't connected anymore.

 

Thanks for the input. I tried Marlin Crawler, they said they just don't deal with setups like mine and suggested taking it to a dealer. I want to avoid that.

 

is your truck a manual or an automatic?

 

It is an auto - A340H. It has an electrical and hydraulic component to control the transfer case.

 

Now I am pretty sure that Marlin offers a dual-stick setup that allows you to use low range independent of the 4wd. So your statement of them not being able to help you with your setup just doesn't fit with what I've heard and read. I can't imagine that the auto-tranny really makes that much difference in the transfer case. You should be able to remove the console, then get at the shifter from the top and the underside. Then you may be able to see if something is broken, bent or disconnected.

 

Are you aware that the automatic tranny has to be in neutral in order to shift in and out of low?

 

According to the owner's manual, you do NOT have to be in N to shift. However, I have tried that several times just to check. The linkages on the outside of the trans are not binding, just something internal will not let the lo range disengage.

 

Nothing is bent or visually wrong when inspecting the transmission and transfer case from the exterior and it does not bind when operating the lever. I was asking Marlin to help me figure out what was going on, not if they had something to replace it. They did not know what to tell me. The auto trans with the ADD makes a big difference with the addition of an entire hydraulic control unit that bolts between the tcase and the trans. In that unit is an entire valve body designed to control the clutches that engage and disengage the trans case. There is also a solenoid in there that controls the 4lo range engage and disengage. What a PITA!

 

I have this same problem..where the hell is the # 4 solenoid?? did you ever get this fixed? My truck locked into 4 l range all by itsself...the front driveshaft is free the gearing is what is locked......no codes no nothin!!!!

 

yeah you can shift from 2wd into 4wd on the fly, but you CAN NOT shift from high into low unless the auto tranny is in neutral. Doing so can and WILL result is damage to the t case, and/or the tranny. if you tryed shifting it from high into low while in drive, or moving i would say there is your problem and you should start looking for a new t case.

 

Wrong!!!! you can shift between 4hi and 4 lo...this is not the issue however!!!

 

you cant shift from damn 4hi to 4lo if your rolling !!! You might can with it in gear NOT MOVING, but it still isnt good for it, and if you read the owners manual closely it susgests you shift to neutral and being stoped before shifting from hi to lo. no wonder your transfer case dosnt work. maybe its because you dont know how to work it !

 

On this model you can shift on the fly from 4H to 4L at speeds less than 20mph (approximately).

 

Are you sure your locked in 4lo. Maybe tranny just not shifting which makes it feel like 4lo. Z

 

I should've replied to this a while back. The answer is yes, I did get it fixed and no, nothing was broken, bent or otherwise. This transmission/transfer case setup is unique. The transfer case has its own valve body, just like the trans does. Therefore it has valves that are prone to stick in the valve body if you do not engage 4x4 very often or change the atf.
Once I dropped the tcase pan and inspected the valve body, it was obvious. By manually actuating the valves, I could tell one or two of them were hanging up. Tapped it and they freed up. Would've been fine at that probably, but I went ahead and pulled it down and cleaned it. Smooth as butter again. Thanks for all the previous input.

 

Thanks for the follow up!
This helps others who get stuck with the same problem later.