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Home >> Ford >> 1995 >> Explorer 2D Utility, 4WD, Automatic >> Repair and Diagnosis >> Transmission >> Transfer Case >> Diagnosis & Overhaul - Borg-WARNER 1354 & 4405 Transfer Case >> Pinpoint Tests >> Pinpoint Test "B" Cannot Change 4WD Gears DTC P1820, P1822, P1824, P1826, P1826, P1828, P1830, P1838, P1846, P1848, P1850, P1852, P1854, P1856, P1858, P1860, P1862, P1864, P1866 & P1867

Pinpoint Test "B" Cannot Change 4WD Gears DTC P1820, P1822, P1824, P1826, P1826, P1828, P1830, P1838, P1846, P1848, P1850, P1852, P1854, P1856, P1858, P1860, P1862, P1864, P1866 & P1867

  1. Check Fuse No. 27

    Remove and check fuse no 27. If fuse is open go to next step. If fuse is okay, go to step 3).

  2. Check Gray Wire For Open

    Turn ignition off. Disconnect transfer case relay module (located behind center of instrument panel). Check for Continuity between GEM harness connector terminal No. 16 and transfer case relay harness connector terminal No. 8. See Fig 1 . If continuity exists, go to next step. If continuity does not exist, repair open Gray wire. Clear and recheck for DTCs.
    Fig 1: Transfer Case Relay Module Harness Connector Terminals
    G96G04685Courtesy of FORD MOTOR CO.

  3. Check Gray Wire For Short To Ground

    Turn ignition off. Check for continuity to ground at GEM harness connector C3 terminal No. 16. If continuity does not exist, go to next step. If continuity exists, repair short to ground in Gray wire. Clear and recheck for DTCs.

  4. Check Transfer Case Relay Module

    Turn ignition off. Disconnect transfer case relay module. Check for continuity between relay module terminals No. 8 and No. 1. See Fig 1 . If continuity does not exist, go to next step. If continuity exists, replace transfer case relay module.

  5. Check Transfer Case Relay Module For Open

    Turn ignition off. Disconnect transfer case relay module. Measure resistance between relay module terminals No. 8 and No. 5. See Fig 1 . If resistance is 85-140 ohms, go to next step. If resistance is not 85-140 ohms, replace transfer case relay module.

  6. Check Gray Wire For Short To Power

    Turn ignition on. Measure voltage at transfer case relay harness connector terminal No. 8. If battery voltage does not exist, go to next step. If battery voltage exists, repair Gray wire for short to power. Clear and recheck for DTCs.

  7. Check Transfer Case Relay Module For Open

    Turn ignition off. Disconnect transfer case relay module. Measure resistance between relay module terminals No. 8 and No. 5. See Fig 1 . If resistance is 85-140 ohms, go to next step. If resistance is not 85-140 ohms, replace transfer case relay module.

  8. Check Yellow Wire For Short To Ground

    Turn ignition off. Disconnect GEM harness connector. Check for continuity to ground at GEM harness connector C3 terminal No. 15. If continuity does not exist, go to next step. If continuity exists, repair short to ground in Yellow wire. Clear and recheck for DTCs.

  9. Check Clutch Relay For Short

    With relay removed, check for continuity between Light Blue/Black wire terminal and Brown wire terminal on relay. If continuity exists, replace relay. If continuity does not exist, go to next step.

  10. Check Light Blue/Black Wire For Battery Voltage

    With clutch relay removed, measure voltage at Light Blue/Black wire at clutch relay harness connector. If battery voltage exists, go to next step. If battery voltage does not exist, repair open Light Blue/Black wire. Clear and recheck for DTCs.

  11. Check For Open Yellow Wire

    With GEM and clutch relay disconnected. Measure resistance of Yellow wire between GEM connector C3 terminal No. 15 and clutch relay harness connector. If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, repair open Yellow wire. Clear and recheck for DTCs.

  12. Check Yellow Wire For Short To Power

    With clutch relay removed, turn ignition on. Measure voltage at Yellow wire at clutch relay harness connector terminal. If battery voltage does not exist, go to next step. If battery voltage exists, repair Yellow wire for short to power. Clear and recheck for DTCs.

  13. Check Clutch Relay For Short

    With relay removed, measure resistance between Black wire terminal and Yellow wire terminal on relay. If resistance is 1000-1800 ohms, go to next step. If resistance is not 1000-1800 ohms, replace relay.

  14. Check Fuse 27

    Remove and check fuse No. 27 for open. If fuse is okay go to next step. If fuse is blown go to step 17).

  15. Check Brown/Pink Wire For Short To Battery

    Disconnect GEM connector C3. Measure voltage between GEM harness connector terminal No. 17 and ground. If battery voltage does not exist, go to next step. If battery voltage exists, repair Brown/Pink wire for short to battery voltage.

  16. Check Brown/Pink Wire For Open

    Disconnect transfer case relay module. Disconnect GEM harness connector C3. Check continuity of Brown/Pink wire between transfer case relay module and GEM harness connector C3 terminal No. 17. If continuity exists, go to next step. If continuity does not exist, repair open Brown/Pink wire. Clear and recheck for DTCs.

  17. Check Light Green/Orange Wire For Open

    Remove fuse No. 27. Check continuity between Light Green/Orange wire at fuse cavity No. 27. If continuity does not exist, go to next step. If continuity exists, repair Light Green/Orange wire for short to ground.

  18. Check Transfer Case Relay Module

    Remove transfer case relay module. Check continuity between relay terminals No. 6 and 10; and terminals No. 3 and 10. See Fig 1 . If continuity does not exist, go to next step. If continuity exists, replace transfer case relay module.

  19. Check Light Green/Orange Wire For Open

    Check continuity of Light Green/Orange wire between transfer case relay module harness connector terminal No. 6 and fuse No. 27 cavity. If continuity does not exist, repair open Light Green/Orange wire. Clear and recheck for DTCs. If continuity exists, replace fuse No. 27. Clear and recheck for DTCs.

  20. Check Pink Wire For Short To Ground

    Turn ignition off. Remove fuse No. 27. Check Pink wire for continuity to ground at fuse cavity No. 27. If continuity exists, repair shorted Pink wire. If continuity does not exist, system is okay. Clear and recheck for DTCs.

  21. Check Brown/Pink Wire For Short To Battery

    Disconnect GEM connector C3. Measure voltage between GEM harness connector C3 terminal No. 17 and ground. If battery voltage does not exist, go to next step. If battery voltage exists, repair Brown/Pink wire for short to battery voltage.

  22. Check 4X4 Fuses

    Check TRANSFER CASE SHIFT RELAY (20-amp) for open. If fuse is okay, go to next step. If fuse is blown, go to step 17).

  23. Check Transfer Case Clutch Relay

    Disconnect transfer case clutch relay. Check for continuity between 6Light Blue/Black wire terminal and Brown wire terminal on relay. If continuity exists, replace relay. If continuity does not exist, go to next step.

  24. Check Orange Wire For Short To Ground

    Check for continuity between Orange wire at transfer case relay module and ground. If continuity does not exist, go to next step. If continuity exists, repair Orange wire for short to ground. Clear and recheck for DTCs.

  25. Check Orange Wire For Short

    Disconnect transfer case relay module. Disconnect accessory delay relay (Explorer only). Turn ignition on. Measure voltage on Orange wire at relay harness connector. If battery voltage exists, repair Orange wire for short to power. If battery voltage does not exist, go to next step.

  26. Check Orange Wire For Open

    Disconnect transfer case harness connector. Check continuity of Orange wire between transfer case relay module harness connector and transfer case harness connector. If continuity exists, go to next step. If continuity does not exist, repair open Orange wire.

  27. Check Brown Wire For Short To Power

    Disconnect transfer case relay module. Turn ignition on. Measure voltage on Brown wire at relay harness connector. If battery voltage exists, repair Brown wire for short to power. Clear and recheck for DTCs. If battery voltage does not exist, go to next step.

  28. Check Brown Wire For Open

    Disconnect transfer case harness connector. Check continuity of Brown wire between transfer case relay module harness connector and transfer case harness connector. If continuity exists, go to next step. If continuity does not exist, repair open Brown wire. Clear and recheck for DTCs.

  29. Check Brown Wire For Short To Ground

    With transfer case and transfer case relay module disconnected, check Brown wire for continuity to ground. If continuity does not exist, go to next step. If continuity exists, repair Brown wire for short to ground. Clear and recheck for DTCs.

  30. Check Yellow Wire For Short To Ground

    With transfer case relay module disconnected, check Yellow wire for continuity to ground. If continuity does not exist, go to next step. If continuity exists, repair Yellow wire for short to ground. Clear and recheck for DTCs.

  31. Check Yellow Wire For Short To Power

    Disconnect transfer case relay module. Turn ignition on. Measure voltage on Yellow wire at relay harness connector. If battery voltage does not exist, go to next step. If battery voltage exists, repair Yellow wire for short to power. Clear and recheck for DTCs.

  32. Check Yellow Wire For Open

    Disconnect transfer case harness connector. Check continuity of Yellow wire between transfer case relay module harness connector and transfer case harness connector. If continuity exists, go to next step. If continuity does not exist, repair open Yellow wire. Clear and recheck for DTCs.

  33. Check Purple/Yellow Wire For Short To Ground

    Turn ignition off. Disconnect GEM harness connector C3. Disconnect transfer case harness connector. Check for continuity between Purple/Yellow wire at transfer case harness connector and ground. If continuity does not exist, go to next step. If continuity exists, repair Purple/Yellow wire for short to ground. Clear and recheck for DTCs.

  34. Check Purple/Yellow Wire For Open

    Turn ignition off. Disconnect GEM harness connector C3. See Figure . Disconnect transfer case harness connector. Check for continuity of Purple/Yellow wire between transfer case harness connector and GEM harness connector C3 terminal No. 21. If continuity does not exist, repair open Purple/Yellow wire. Clear and recheck for DTCs. If continuity exists, replace transfer case shift motor. Clear and recheck for DTCs.

  35. Check White Wire For Short To Ground

    Turn ignition off. Disconnect GEM harness connector C3. Disconnect transfer case harness connector. Check for continuity between White wire at transfer case harness connector and ground. If continuity does not exist, go to next step. If continuity exists, repair White wire for short to ground. Clear and recheck for DTCs.

  36. Check White Wire For Open

    Turn ignition off. Disconnect GEM harness connector C3. See Figure . Disconnect transfer case harness connector. Check for continuity of White wire between transfer case harness connector and GEM harness connector C3 terminal No. 20. If continuity does not exist, repair open White wire. Clear and recheck for DTCs. If continuity exists, replace transfer case shift motor. Clear and recheck for DTCs.

  37. Check Brown/White Wire For Short To Ground

    Turn ignition off. Disconnect GEM harness connector C3. Disconnect transfer case harness connector. Check for continuity between Brown/White wire at transfer case harness connector and ground. If continuity does not exist, go to next step. If continuity exists, repair Brown/White wire for short to ground. Clear and recheck for DTCs.

  38. Check Brown/White Wire For Open

    Turn ignition off. Disconnect GEM harness connector C3. See Figure . Disconnect transfer case harness connector. Check for continuity of Brown/White wire between transfer case harness connector and GEM harness connector C3 terminal No. 19. If continuity does not exist, repair open Brown/White wire. Clear and recheck for DTCs. If continuity exists, replace transfer case shift motor. Clear and recheck for DTCs.

  39. Check Orange/White Wire For Short To Ground

    Turn ignition off. Disconnect GEM harness connector C3. Disconnect transfer case harness connector. Check for continuity between Orange/White wire at transfer case harness connector and ground. If continuity does not exist, go to next step. If continuity exists, repair Orange/White wire for short to ground. Clear and recheck for DTCs.

  40. Check Orange/White Wire For Open

    Turn ignition off. Disconnect GEM harness connector C3. See Figure . Disconnect transfer case harness connector. Check for continuity of Orange/White wire between transfer case harness connector and GEM harness connector C3 terminal No. 18. If continuity does not exist, repair open Orange/White wire. Clear and recheck for DTCs. If continuity exists, replace transfer case shift motor. Clear and recheck for DTCs.

  41. Check Yellow/White Wire For Short To Ground

    Turn ignition off. Disconnect GEM harness connector C3. Disconnect transfer case harness connector. Check for continuity between Yellow/White wire at transfer case harness connector and ground. If continuity does not exist, go to next step. If continuity exists, repair Yellow/White wire for short to ground. Clear and recheck for DTCs.

  42. Check Yellow/White Wire For Open

    Turn ignition off. Disconnect GEM harness connector C3. See Figure . Disconnect transfer case harness connector. Check for continuity of Yellow/White wire between transfer case harness connector and GEM harness connector C3 terminal No. 12. If continuity does not exist, repair open Yellow/White wire. Clear and recheck for DTCs. If continuity exists, replace transfer case shift motor. Clear and recheck for DTCs.

  43. Check Yellow/White Wire For Short To Power

    Turn ignition off. Disconnect GEM harness connector C3. See Figure . Disconnect transfer case harness connector. Measure voltage between Yellow/White wire at GEM harness connector C3 terminal No. 12 and ground. If battery voltage does not exist, go to next step. If battery voltage exists, repair Yellow/White wire for short to power. Clear and recheck for DTCs.

  44. Check Transfer Case Motor For Short

    Reconnect transfer case shift motor and GEM harness connectors. Turn ignition on. Backprobe GEM harness connector C3 terminal No. 12 for battery voltage. See Figure . If battery voltage does not exist, clear and recheck for DTCs. If battery voltage exists, replace transfer case shift motor. Clear and recheck for DTCs.

  45. Check Purple/Yellow Wire For Short To Power

    Remove GEM harness connector C3. Turn ignition on. Measure voltage between GEM connector C3 terminal No. 21. and ground. See Figure . If battery voltage does not exist, replace GEM with known good unit. Clear and recheck for DTCs. If battery voltage exists, disconnect shift motor harness connector. If battery voltage still exists, repair Purple/Yellow wire for short to power. If battery voltage does not exist with transfer case disconnected, replace transfer case shift motor. Clear and recheck for DTCs.

  46. Check White Wire For Short To Power

    Remove GEM harness connector C3. Turn ignition on. Measure voltage between GEM connector C3 terminal No. 20. and ground. See Figure . If battery voltage does not exist, replace GEM with known good unit. Clear and recheck for DTCs. If battery voltage exists, disconnect shift motor harness connector. If battery voltage still exists, repair White wire for short to power. If battery voltage does not exist with transfer case disconnected, replace transfer case shift motor. Clear and recheck for DTCs.

  47. Check Brown/White Wire For Short To Power

    Remove GEM harness connector C3. Turn ignition on. Measure voltage between GEM connector C3 terminal No. 19. and ground. See Figure . If battery voltage does not exist, replace GEM with known good unit. Clear and recheck for DTCs. If battery voltage exists, disconnect shift motor harness connector. If battery voltage still exists, repair Brown/White wire for short to power. If battery voltage does not exist with transfer case disconnected, replace transfer case shift motor. Clear and recheck for DTCs.

  48. Check Orange/White Wire For Short To Power

    Remove GEM harness connector C3. Turn ignition on. Measure voltage between GEM connector C3 terminal No. 18. and ground. See Figure . If battery voltage does not exist, replace GEM with known good unit. Clear and recheck for DTCs. If battery voltage exists, disconnect shift motor harness connector. If battery voltage still exists, repair Orange/White wire for short to power. If battery voltage does not exist with transfer case disconnected, replace transfer case shift motor. Clear and recheck for DTCs.
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