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Ford 2000 Ranger Workshop Manual
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Ford 2000 Ranger Workshop Manual

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2000 Ranger Workshop Manual
SECTION 308-07A: Transfer Case — General Information
DIAGNOSIS AND TESTING
Transfer Case
Refer to Wiring Diagrams Cell 34, Electronic Shift Control for schematic and connector information.
Refer to Wiring Diagrams Cell 59, Generic Electronic Module for schematic and connector information.
Special Tool(s)
73III Automotive Meter
105-R0057 or equivalent
Worldwide Diagnostic System (WDS)
418-F224,
New Generation STAR (NGS) Tester
418-F052, or equivalent scan tool
R-134A Manifold Gauge Set or equivalent
176-R032A
Seal Depth Set/Vacuum Test Cap or equivalent
205-400
Seal Replacer/CV Tester or equivalent
205-399
Vacuum Pump or equivalent
014-R1054
Vacuum Test Cap or equivalent
205-401
Pulse Vacuum Hublock Vacuum Schematic
http://www.fordtechservice.dealerconnection.com/pubs/content/~WSYL/~MUS~LEN/21/...
Page 1 of 62
2000 Ranger Workshop Manual
Procedure revision date: 06/18/1999
1/18/2012

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  • Page 1 2000 Ranger Workshop Manual Page 1 of 62 SECTION 308-07A: Transfer Case — General Information 2000 Ranger Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 06/18/1999 Transfer Case Refer to Wiring Diagrams Cell 34, Electronic Shift Control for schematic and connector information.
  • Page 2 2000 Ranger Workshop Manual Page 2 of 62 Inspection and Verification 1. NOTE: The GEM/CTM must be reconfigured upon replacement. Refer to the scan tool help screen on the configuration card to program the tire size and axle ratio. The transfer case is a generic electronic module (GEM) controlled system.
  • Page 3 2000 Ranger Workshop Manual Page 3 of 62 B1304 Accessory Delay Relay Coil Circuit REFER to Section 501-11. Short to Battery B1313 Battery Saver Relay Coil — Circuit GEM/CTM REFER to Section 417-02. Failure B1315 Battery Saver Relay Coil Circuit...
  • Page 4 2000 Ranger Workshop Manual Page 4 of 62 B1840 Wiper Power Circuit Failure GEM/CTM REFER to Section 501-16. B2141 NVM Configuration Failure GEM/CTM Vehicle speed calibration is not programmed into the GEM/CTM. REFER to the scan tool help screen on the configuration card to program the tire size and axle ratio.
  • Page 5 2000 Ranger Workshop Manual Page 5 of 62 NTRL_SW Neutral Safety Switch Input NTRL, not NTRL MTR_CCW Transmission Transfer CCW Motor Output (GEM Only) ON---, OFF---, OFFO-G, ON-B- MTR_CW CW Shift Relay Coil Status (GEM Only) OFF---, ON---, OFFO-G, ON-B-...
  • Page 6 2000 Ranger Workshop Manual Page 6 of 62 B1450 Wiper/Wash Interval Delay Switch Input Circuit Failure GEM/CTM B1453 Wiper/Wash Interval Delay Switch Input Short to Ground GEM/CTM B1462 Seat Belt Switch Circuit Failure GEM/CTM B1577 Park Lamp Input Circuit Short to Battery...
  • Page 7 2000 Ranger Workshop Manual Page 7 of 62 CAUTION: Be careful when probing the fuse junction panel, power distribution box or any connectors. Damage will result to the connector receptacle if the probe or terminal being used is too large.
  • Page 8 2000 Ranger Workshop Manual Page 8 of 62 If DTC P1854, GO to If DTC P1858, GO to If DTC P1863, GO to If DTC P1866, GO to If DTC P1867, GO to If DTC P1891, GO to GO to A3.
  • Page 9 2000 Ranger Workshop Manual Page 9 of 62 Does the PID indicate 4WD HIGH? GO to A7. GO to A8. A7 CHECK THE 4X4 MODE SWITCH — MONITOR THE GEM PID 4WD_SW Monitor the GEM PID 4WD_SW. Place the mode switch in the 4X4 LOW position.
  • Page 10 2000 Ranger Workshop Manual Page 10 of 62 Is the resistance between 3700 and 4100 ohms? GO to A9. REPLACE the mode switch. CLEAR the DTCs. TEST the system for normal operation. A9 CHECK THE 4X4 MODE SWITCH IN THE 4X4 HIGH POSITION Place the mode switch in the 4X4 HIGH position.
  • Page 11 2000 Ranger Workshop Manual Page 11 of 62 4X4 Mode Switch C225 GEM C223 Measure the resistance between mode switch C225-3, circuit 465 (W/LB), and GEM C223-8, circuit 465 (W/LB). Is the resistance less than 5 ohms? GO to A12.
  • Page 12 2000 Ranger Workshop Manual Page 12 of 62 4X4 Mode Switch C225 GEM C221 Measure the resistance between mode switch C225-2, circuit 359 (GY/R), and GEM C221-21, circuit 359 (GY/R). Is the resistance less than 5 ohms? GO to A15.
  • Page 13 2000 Ranger Workshop Manual Page 13 of 62 Turn the 4X4 mode switch to the 2WD position. NOTE: When 4X4 is disengaged, the front driveshaft may spin due to viscous drag in the transfer case, especially if cold. If this occurs, the front drive line can easily be stopped.
  • Page 14 2000 Ranger Workshop Manual Page 14 of 62 Is any voltage indicated? REPAIR circuit 275 (Y). CLEAR the DTCs. TEST the system for normal operation. REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal operation.
  • Page 15 2000 Ranger Workshop Manual Page 15 of 62 Measure the voltage between battery saver relay connector pin 2, circuit 1005 (P/O), and ground. Is any voltage indicated? REPAIR circuit 1005 (P/O). CLEAR the DTCs. TEST the system for normal operation.
  • Page 16 2000 Ranger Workshop Manual Page 16 of 62 Are the voltages greater than 10 volts? REPAIR open in circuit 792 (T/Y). REPLACE the fuse. CLEAR the DTCs. TEST the system for normal operation. GO to A28. A28 CHECK FUSE JUNCTION PANEL FUSE 26 (10A)
  • Page 17 2000 Ranger Workshop Manual Page 17 of 62 Is the resistance greater than 10,000 ohms? GO to A31. REPAIR circuit 705 (LG/O). TEST the system for normal operation. A31 CHECK CIRCUIT 705 (LG/O) FOR OPEN Measure the resistance between battery saver relay connector pin 3, circuit 705 (LG/O), and clutch relay connector pin 2, circuit 705 (LG/O).
  • Page 18 2000 Ranger Workshop Manual Page 18 of 62 Is the resistance greater than 10,000 ohms? GO to A34. REPAIR circuit 275 (Y). TEST the system for normal operation. A34 CHECK CIRCUIT 1005 (P/O) FOR SHORT TO GROUND Measure the resistance between battery saver relay connector pin 2, circuit 1005 (P/O), and ground.
  • Page 19 2000 Ranger Workshop Manual Page 19 of 62 Is the voltage greater than 10 volts? GO to A37. GO to A38. A37 CHECK CIRCUIT 779 (BR) FOR VOLTAGE — GEM ACTIVE COMMAND SHIFT CLUTCH OFF Trigger the GEM active command SHIFT CLUTCH to OFF.
  • Page 20 2000 Ranger Workshop Manual Page 20 of 62 Is the voltage greater than 10 volts? GO to A40. CHECK power distribution box mini-fuse 3 (20A). REPLACE if necessary. If OK, REPAIR circuit 704 (DG/LG). CLEAR the DTCs. TEST the system for normal operation.
  • Page 21 2000 Ranger Workshop Manual Page 21 of 62 Is the voltage greater than 10 volts? GO to A44. REPAIR circuit 705 (LG/O). CLEAR the DTCs. TEST the system for normal operation. A44 CHECK CIRCUIT 513 (BR/PK) FOR OPEN GEM C223 Measure the resistance between JSO relay C230-9, circuit 513 (BR/PK), and GEM C223-17, circuit 513 (BR/PK).
  • Page 22 2000 Ranger Workshop Manual Page 22 of 62 GO to A49. REPAIR circuit 513 (BR/PK) and/or circuit 339 (GY). CLEAR the DTCs. TEST the system for normal operation. A47 CHECK CIRCUIT 339 (GY) FOR SHORT TO POWER JSO Relay C230 GEM C223 Measure the voltage between JSO relay C230-8, circuit 339 (GY), and ground.
  • Page 23 2000 Ranger Workshop Manual Page 23 of 62 Are the resistance(s) between 60 and 110 ohms? REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal operation. REPLACE the JSO relay. CLEAR the DTCs. TEST the system for normal operation.
  • Page 24 2000 Ranger Workshop Manual Page 24 of 62 Trigger the GEM active command CW/CCW to OFF. Measure the voltage between transfer case electric shift motor C1001-4, circuit 777 (Y), and ground; and between transfer case electric shift motor C1001-7, circuit 778 (O), and ground.
  • Page 25 2000 Ranger Workshop Manual Page 25 of 62 Are the resistances less than 5 ohms? RECONNECT the transfer case electric shift motor. GO to GO to A57. A55 CHECK CIRCUIT 777 (Y) FOR OPEN JSO Relay C230 Measure the resistance between JSO relay, C230-7, circuit 777 (Y), and transfer case electric shift motor C1001- 4, circuit 777 (Y).
  • Page 26 2000 Ranger Workshop Manual Page 26 of 62 Is the resistance less than 5 ohms? REPLACE the JSO relay. CLEAR the DTCs. TEST the system for normal operation. REPAIR circuit 57 (BK). CLEAR the DTCs. TEST the system for normal operation.
  • Page 27 2000 Ranger Workshop Manual Page 27 of 62 Does the GEM PID PLATE_D change states? GO to A62. GO to A60. A60 CHECK CIRCUIT 771 (P/Y) FOR SHORT TO POWER Transfer Case Electric Shift Motor C1001 GEM C223 Measure the voltage between transfer case electric shift motor C1001-5, circuit 771 (P/Y), and ground.
  • Page 28 2000 Ranger Workshop Manual Page 28 of 62 GO to A62. REPAIR circuit 771 (P/Y). CLEAR the DTCs. TEST the system for normal operation. If the concern remains, RECONNECT GEM C223. GO to A62 CHECK CIRCUIT 771 (P/Y) FOR OPEN Measure the resistance between transfer case electric shift motor C1001-5, circuit 771 (P/Y), and GEM C223-21, circuit 771 (P/Y).
  • Page 29 2000 Ranger Workshop Manual Page 29 of 62 Transfer Case Electric Shift Motor C1001 GEM C223 Measure the voltage between transfer case electric shift motor C1001-1, circuit 770 (W), and ground. Is any voltage indicated? REPAIR circuit 770 (W). CLEAR the DTC. TEST the system for normal operation.
  • Page 30 2000 Ranger Workshop Manual Page 30 of 62 Connect a jumper wire between transfer case electric shift motor C1001-6, circuit 762 (Y/W), and C1001-2, circuit 764 (BR/W). Does the GEM PID PLATE_B change states? GO to A71. GO to A69.
  • Page 31 2000 Ranger Workshop Manual Page 31 of 62 REPAIR circuit 764 (BR/W). CLEAR the DTCs. TEST the system for normal operation. If the concern remains, RECONNECT GEM C223. GO to A71 CHECK CIRCUIT 764 (BR/W) FOR OPEN Measure the resistance between transfer case electric shift motor C1001-2, circuit 764 (BR/W), and GEM C233- 19, circuit 764 (BR/W).
  • Page 32 2000 Ranger Workshop Manual Page 32 of 62 Is any voltage indicated? REPAIR circuit 763 (O/W). CLEAR the DTC. TEST the system for normal operation. GO to A74. A74 CHECK CIRCUIT 763 (O/W) FOR SHORT TO GROUND Measure the resistance between transfer case electric shift motor C1001-3, circuit 763 (O/W), and ground.
  • Page 33 2000 Ranger Workshop Manual Page 33 of 62 Monitor the GEM PID IGN_GEM while turning the ignition switch through the RUN, OFF and ACC positions. Do the PID values agree with the ignition switch positions? GO to B2. REFER to Section 417-02.
  • Page 34 2000 Ranger Workshop Manual Page 34 of 62 Monitor the GEM PID 4WD_SW. Does the PID indicate 2WD? GO to B6. GO to B8. If the PID indicates OFFO-G, GO to B6 CHECK THE 4X4 MODE SWITCH — MONITOR THE GEM PID 4WD_SW IN THE 4X4 HIGH POSITION Place the mode switch in the 4X4 HIGH position.
  • Page 35 2000 Ranger Workshop Manual Page 35 of 62 4X4 Mode Switch C225 Place the mode switch in the 2WD position. Measure the resistance between the mode switch terminals 2 and 3. Is the resistance between 3700 and 4100 ohms? GO to B9.
  • Page 36 2000 Ranger Workshop Manual Page 36 of 62 Measure the resistance between the mode switch terminals 2 and 3. Is the resistance between 340 and 380 ohms? GO to B11. REPLACE the mode switch. CLEAR the DTCs. TEST the system for normal operation.
  • Page 37 2000 Ranger Workshop Manual Page 37 of 62 Is any voltage indicated? REPAIR circuit 465 (W/LB). CLEAR the DTCs. TEST the system for normal operation. GO to B13. B13 CHECK CIRCUIT 465 (W/LB) FOR SHORT TO GROUND Measure the resistance between GEM C223-8, circuit 465 (W/LB), and ground.
  • Page 38 2000 Ranger Workshop Manual Page 38 of 62 Is the resistance greater than 10,000 ohms? GO to B16. REPAIR circuit 359 (GY/R). CLEAR the DTCs. TEST the system for normal operation. B16 CHECK CIRCUIT 359 (GY/R) FOR SHORT TO POWER Measure the voltage between GEM C221-21, circuit 359 (GY/R), and ground.
  • Page 39 2000 Ranger Workshop Manual Page 39 of 62 Is the voltage greater than 10 volts? GO to B19. CHECK fuse 9 (7.5A). REPLACE if necessary. If OK, REPAIR circuit 276 (BR). CLEAR the DTCs. TEST the system for normal operation.
  • Page 40 2000 Ranger Workshop Manual Page 40 of 62 Does the GEM PID NTRL_SW indicate correctly? GO to B24. GO to B22. B22 CHECK THE GROUND TO THE DIGITAL TR SENSOR — CIRCUIT 57 (BK) Digital TR Sensor C1005 Measure the resistance between digital TR sensor C1005-7, circuit 57 (BK), and ground.
  • Page 41 2000 Ranger Workshop Manual Page 41 of 62 Measure the resistance between GEM C224-18, circuit 519 (LG/BK), and ground. Are the resistances greater than 10,000 ohms? GO to B25. REPAIR circuit 523 (R/PK) and/or 519 (LG/BK). CLEAR the DTCs. TEST the system for normal operation.
  • Page 42 2000 Ranger Workshop Manual Page 42 of 62 Is any voltage indicated? REPAIR circuit 523 (R/PK) and/or 519 (LG/BK). CLEAR the DTCs. TEST the system for normal operation. GO to B27. B27 CHECK THE VEHICLE SPEED SIGNAL — MONITOR THE GEM PID VSS_GEM...
  • Page 43 2000 Ranger Workshop Manual Page 43 of 62 Is the resistance less than 5 ohms? REFER to Section 206-09B. REPAIR circuit 679 (GY/BK). CLEAR the DTCs. TEST the system for normal operation. PINPOINT TEST C: THE 4X4 HIGH AND/OR 4X4 LOW INDICATOR(S) DO/DOES NOT OPERATE PROPERLY...
  • Page 44 2000 Ranger Workshop Manual Page 44 of 62 If DTC P1804, GO to If DTC P1806, GO to If DTC P1808, GO to If DTC P1810, GO to GO to C3. C3 VERIFY THE INOPERATIVE INDICATOR LAMP Verify the inoperative indicator lamp.
  • Page 45 2000 Ranger Workshop Manual Page 45 of 62 C7 CHECK CIRCUIT 784 (LB/BK) FOR SHORT TO GROUND Measure the resistance between GEM C223-10, circuit 784 (LB/BK), and ground. Is the resistance greater than 10,000 ohms? RECONNECT instrument cluster C214. GO to REPAIR circuit 784 (LB/BK).
  • Page 46 2000 Ranger Workshop Manual Page 46 of 62 Is the resistance greater than 10,000 ohms? GO to C11. REPAIR circuit 783 (GY). CLEAR the DTCs. TEST the system for normal operation. C11 CHECK THE INSTRUMENT CLUSTER Connect a jumper wire between GEM C223-14, circuit 783 (GY), and ground.
  • Page 47 2000 Ranger Workshop Manual Page 47 of 62 REPAIR circuit 784 (LB/BK). CLEAR the DTCs. TEST the system for normal operation. GO to C13. C13 CHECK CIRCUIT 783 (GY) FOR SHORT TO POWER Measure the voltage between GEM C223-14, circuit 783 (GY), and ground.
  • Page 48 2000 Ranger Workshop Manual Page 48 of 62 Is the voltage greater than 10 volts? GO to D4. REPAIR circuit 1052 (T/BK). CLEAR the DTCs. TEST the system for normal operation. D4 CHECK THE VOLTAGE TO THE GEM/CTM — CIRCUIT 1001 (W/Y) GEM/CTM C224 Measure the voltage between GEM/CTM C224-11, circuit 1001 (W/Y), and ground.
  • Page 49 2000 Ranger Workshop Manual Page 49 of 62 Is the resistance less than 5 ohms? REFER to Section 418-00. REPAIR circuit 519 (LG/BK) or 57 (BK). CLEAR the DTCs. TEST the system for normal operation. PINPOINT TEST E: THE PULSE VACUUM HUBLOCKS DO NOT OPERATE PROPERLY (TRANSFER CASE MOTOR MOVEMENT AND FRONT DRIVE SHAFT OPERATE...
  • Page 50 2000 Ranger Workshop Manual Page 50 of 62 A/C Vacuum Input Line Connect a hand vacuum pump to the A/C vacuum input line connector and try to pull a vacuum to 15 in/Hg. Does the vacuum drop exceed 0.5 in/Hg in 30 seconds? DIAGNOSE the A/C system;...
  • Page 51 2000 Ranger Workshop Manual Page 51 of 62 E6 CHECK THE ENGINE AND PRIMARY VACUUM LINE FOR VACUUM Engine Vacuum Output Connector Connect a vacuum gauge to the engine vacuum output connector and measure the vacuum level. Is the vacuum level greater than 11 in/Hg? REPAIR or REPLACE the vacuum reservoir or vacuum lines between the PVH solenoid vacuum input line and vacuum reservoir input line.
  • Page 52 2000 Ranger Workshop Manual Page 52 of 62 Does the vacuum gauge indicate at least 11 in/Hg after six seconds but not longer than 60 seconds after switching the 4X4 mode switch to 4X4 HIGH? GO to E9. GO to E10.
  • Page 53 2000 Ranger Workshop Manual Page 53 of 62 PVH Solenoid C185 Measure the voltage between PVH solenoid C185-2, circuit 298 (P/O), and ground. Is the voltage greater than 10 volts? GO to E12. REPAIR circuit 298 (P/O). TEST the system for normal operation.
  • Page 54 2000 Ranger Workshop Manual Page 54 of 62 Is the voltage greater than 9 volts after three seconds but not more than 60 seconds after switching the 4X4 mode switch to 4X4 HIGH? GO to E15. GO to E17. E15 CHECK THE GEM 4X4 DISENGAGE SEQUENCE AND CIRCUIT 77 (DB/Y) — 4X4 HIGH TO 2WD Measure the voltage between PVH solenoid C185-2, circuit 298 (P/O), and PVH solenoid C185-3, circuit 77 (DB/Y) while switching the 4X4 mode switch to 2WD.
  • Page 55 2000 Ranger Workshop Manual Page 55 of 62 Measure the resistance between PVH solenoid C185-1, circuit 599 (PK/LG), and ground; and between PVH solenoid C185-3, circuit 77 (DB/Y), and ground. Are the resistances greater than 10, 000 ohms? GO to E18.
  • Page 56 2000 Ranger Workshop Manual Page 56 of 62 Is any voltage indicated? REPAIR circuit 599 (PK/LG) and/or 77 (DB/Y). CLEAR the DTCs. TEST the system for normal operation. REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for normal operation.
  • Page 57 2000 Ranger Workshop Manual Page 57 of 62 GO to E24. GO to E23. E23 CHECK THE LH SIDE WHEEL END FOR LEAKS Reconnect the RH wheel end vacuum line connector. Disconnect the LH wheel end vacuum line connector. NOTE: This step may require rapid pumping for up to 10 seconds.
  • Page 58 2000 Ranger Workshop Manual Page 58 of 62 RECONNECT the chassis vacuum line to the steel vacuum line. GO to REPLACE the chassis vacuum line. TEST the system for normal operation. E25 BUBBLE TEST THE RUBBER/STEEL VACUUM LINE INTERFACE WARNING: Do not use shop pressure when performing this check.
  • Page 59 2000 Ranger Workshop Manual Page 59 of 62 If bubbles are visible at the hublock/wheel hub interface, REPLACE the hublock/wheel hub O-ring; REFER to Section 204-01B. TEST the system for normal operation. If bubbles are visible at the hublock end, REPLACE the hublock; REFER to Section 204-01B.
  • Page 60 2000 Ranger Workshop Manual Page 60 of 62 Are bubbles visible at the wheel bearing outer seal? REPLACE the wheel hub and bearing; REFER to Section 204-01B. TEST the system for normal operation. GO to E31. E31 BUBBLE CHECK THE WHEEL END SHAFT SEAL Remove the two screws and slide the wheel end shaft seal cover back.
  • Page 61 2000 Ranger Workshop Manual Page 61 of 62 E33 CHECK THE WHEEL END KNUCKLE FOR VACUUM LEAKS Remove the 1/2 shaft retaining ring; refer to Section 204-01B. Remove the hub and bearing; refer to Section 204-01B. Remove the 1/2 shaft.
  • Page 62 2000 Ranger Workshop Manual Page 62 of 62 resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set in volts position and check for voltage at terminal 4.