Complicated 4x4 issue

[spud]

Okay here is as much as I know, believe and think I can provide.

(1) I have a 1999 Ford Expedition XLT with a 4.6 V8, Automatic, 4x4, 3.55 gears with the H8, has running boards with lights in them to see with when you get in and out, heated mirrors, FOB to lock and unlock and a horn feature, dual heat and air, power seats, locks mirrors, 16" factory aluminum wheels, tilt, cruise, center console, and so on. Does not have the air ride or fog lights in the bumper and does not have leather or sunroof or compass.

(2) I took it in a while back to get the ac issue fixed and that required the dash to come out to replace a motor, a flapper and I had them do the heater core at the same time since it was all apart anyway.

(3) I got it back and I can hear rattles and squeaks from the dash, if I press on a spot above the glove box that helps reduce the noise and sometimes makes it stop.

(4) I dont use 4x4 much but I know I had used it before I took it in for the ac issue and it worked fine.

(5) After I got the truck back the 4x4 would only work when things where cold (example less that 10 miles of running).

(6) I never got a chance to take it back to correct the issues for a bit until a couple weeks ago.

(7) I took it in, they diagnosed it as the motor on the side of the transfercase and replaced it. The replacement I was told required them to "wire it up"

(8) I got it back and it did not work at all. The next day it worked but just for a single shot into 4x4 hi then when I put into AWD and then tried to go back into 4x4 hi it did nothing, no solenoid click nothing.

(9) I took it back and they scanned its "GEM MODULE" and there was 5 errors, one saying a short of some sort.

(10) I have to take it back out again to this place for them to re scan since they failed to come get my truck to work on it when we had set an appointment for them to do so.

(11) So Monday I have to go back out but the guy is telling me he believes the "GEM MODULE" is likely bad and needs replaced and says they are like $200 used and you have to find a specific one.

So, this is what I know and I ask if you think the shop is on the right track or could they have simply pinched some wires when they tore the dash apart?

 

[Am3ricanInfid3L]

I would definitely have them look over everything again properly before making any assumptions. If you KNOW your 4x4 was fine before they took apart your dash, they could have jacked something up. I don't know anything about the shop you took it too, but you don't want to fix something that isn't broken. Have you tried putting it in 4low?

 

[lve2wheel]

Sounds like you need to find a new mechanic to me. Just saying. Hope you get all the bugs worked out.

 

[spud]

I would definitely have them look over everything again properly before making any assumptions. If you KNOW your 4x4 was fine before they took apart your dash, they could have jacked something up. I don't know anything about the shop you took it too, but you don't want to fix something that isn't broken. Have you tried putting it in 4low?

Yeah same goes for 4 low, the AWD works (front grabs in loose gravel, sand, dirt) but you can not use the control to select 4wh or 4wl.

Yeah Monday I take it back in and I am gonna run down what I know and tell him I want it in writing that the only problem with the t-case switching is the GEM module if they say that is the issue and if it ends up not being the problem I want them then to agree to a full refund, figure that will show just how "positive" they are.

 

[stamp11127]

If your dash didn't rattle going in then that is crappy work.

Get a list of the GEM codes. A good shop keeps detailed records and should be able to provide a copy of them. I'll check the manual later today on the t-case operation and get back to you.

Sounds like they are parts tossers and don't verify a failure. Anytime you do eletrical work you do not "wire it up". This stuff is plug and play for the most part unless it needs programing.

Feel like turning a few wrenches?

 

[spud]

Would love to be able to turn wrenches again. I guess this is the biggest part that kills me is that actually I am not dumb when it comes to vehicles, in fact pretty smart at it. My last toy was a 1995 Impala SS that I worked on myself and tweaked a bit. Life has its ways of stopping ya though and a simple iced over ICC bumper on a trailer while getting my load locks out took that fun away from me. Pretty crippled up these days so I have to pay for the work to be done and I live in a rural area so few mechanics about to deal with. Pretty much been to all of them 1 time or another and pretty much been taken advantage of 1 time or another as well. Sucks to sit back and know your getting screwed but not much ya can do about it.

 

[spud]

Well hello guys, here is what took place. We did some road testing (dirt roads that is) we did lots of meter and programmer testing, some internet printing and some cussing, some anger at each other and even resorted to a $20 bet but in the end it is confirmed that I have a spastic GEM module (not the official term). My GEM module will work sometimes and all the time and not at all. I had a prior issue that for 2 days my drivers window would not roll up then out of the blue it worked fine, same with the rear wiper, it stopped for a short bit then started working just fine and I have an ABS light on. Now I never mentioned that before because frankly how would one think that a window, a wiper or the brakes would have anything to do with a transfercase? Well in the world of electronic controlled stuff it is in fact connected. My GEM module has something messed up that in the end was tested by ripping the lower dash cover off, removing the ebrake pedal and some other crap so 2 wires could be checked. One was to give a value of .5 ohms and the other a value under 10,000 (somethings) Mine passed the .5 ohms just fine but the 2nd was at 14,000, and that was 4,000 over spec and that confirmed a GEM module issue. We now have it to be able to work every time if I put the truck in nuetral, start it, then select a spot on the selector I want and have to repeat this to release it or engage it again, well it works almost every time. The error codes in the Module all pointed toward a bunch of stuff that when bypassed and tested without the module worked just fine. So 4 hours spent on this today pulling hair. In the end he said the reason why he knew it was the GEM module all along was because normally the only 2 issues they have is the motor on the side going bad or the module so they tend to not waste hours ripping the vehicle apart like that just to test it. Since we did have so much panels off I did quickly run a wire I needed out of the way for my dash camera so that was a bonus and he did not charge me for the 4 hours labor to confirm but I did loose the $20 bet because I swore it was a short in a wire. I say I still came out on top. I ordered the module and when it gets here he will install it.

Oh he also tossed my ebrake pedal for me at my request and is going to help me set it up with a center ebrake pull. I have big feet (size 15) and I am sick and tired of kicking that e brake pedal with my big toe getting in and screaming in pain from it.

Thank you all for your help!!!!

 

[lve2wheel]

Hope that fixes the problem bud! Youve been through hell sounds like.