03 Expy Beach Wagon saga 4x4 inoperative

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sdoherty

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Jun 15, 2015
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Location
virginia
We have an 03 that has served us well as a long distance hauler for all sorts of trips. It only has 130k but the undercarriage is very rusty and we now only use it to drive on the beach in the sand to and from our cottage about 5 miles round trip. A few of the issues this forum has helped me with.

I installed new 1.5 lift struts and springs which are of course one unit. One of the originals(factory) broke at the rear and also bent the rear alignment bar.

Removed the running boards so as not to get hung up in the sand.

Had the rusted/broken brake lines replaced by a shop as I do not do brakes lines.

Installed a front 2 inch receiver hitch.

The trans lines rusted out so I replaced the radiator and did not route the trans lines though the radiator but installed into a separate trans cooler. In hindsight I could have kept the original radiator in the truck and just installed a trans cooler. BTW those quick connects suck.

Last week it would not crank so I checked to wire on the starter for power and there was power so I replaced the started - tough job..

Now for the question :) - the 4X4 stopped working as I had the blinking 3 time 4x4 light on the dash. I removed the transfer case motor and replaced it but now the dash lights no longer flash but I do not hear the new motor turn at all. It is currently in 4x4 high which is good but I am worried with driving on the pavement that something will break. I dont want to try and diagnose the PCM or whatever and was thinking just to cut the wires and install switches to move the transfer case selector. Has anyone tried this?

TIA
 
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