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Test M: 4X4 Indicator Inoperative Or Always On

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: After making any repairs, clear DTCs and perform self-test.
  1. Turn ignition switch to LOCK position. Connect New Generation Star (NGS) tester to Data Link Connector (DLC). DLC is located below center of instrument panel, right of steering column. Observe Generic Electronic Module (GEM) PIDs IGN_S, IGN_R, IGN_O/L and IGN_A while turning ignition switch through all positions. If PID values agree with switch positions, go to next step. If PID values do not agree with switch positions, repair ignition switch circuit(s) as necessary. See POWER DISTRIBUTION in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
  2. Use GEM Diagnostic Trouble Codes (DTCs) recorded from continuous and on-demand self-tests. If no DTCs, or DTC P1804 or P1806 exists, go to next step. If any other DTCs exist, perform appropriate diagnostics. See GENERIC ELECTRONIC MODULE/CENTRAL TIMER MODULE DIAGNOSTIC TROUBLE CODE INDEX  table.
  3. Turn ignition switch to RUN position. Observe GEM PID 4WDHIGH. Toggle GEM active command 4WDHIGH ON and OFF. 4X4 indicator should illuminate, then go out. If 4X4 indicator does not illuminate and PID displays ONO-G, go to next step. If 4X4 indicator operates as specified, verify symptom. See SYMPTOM INDEX  table. If 4X4 indicator does not operate as specified and PID displays ON-B-, go to step  8. If 4X4 indicator stays on continuously and PID displays ONO-G, go to step  6.
  4. Turn ignition switch to LOCK position. Disconnect GEM 22-pin harness connector C201c. GEM is located on back side of central junction box, under left side of instrument panel. Connect fused jumper wire (5-amp) between ground and GEM 22-pin harness connector C201c terminal No. 9 (Light Blue wire). See Fig 1. Turn ignition switch to RUN position. If 4X4 indicator does not illuminate, go to next step. If 4X4 indicator illuminates, go to step  10.
  5. Turn ignition switch to LOCK position. Disconnect instrument cluster 20-pin harness connector C220a. Measure resistance in Light Blue wire between instrument cluster 20-pin harness connector C220a terminal No. 4 and GEM harness connector C201c terminal No. 9. See Figure and Fig 1 . If resistance is 5 ohms or less, go to step  11. If resistance is more than 5 ohms, repair open in Light Blue wire between instrument cluster and GEM.
  6. Turn ignition switch to LOCK position. Disconnect instrument cluster 20-pin harness connector C220a. Disconnect GEM 22-pin harness connector C201c. Measure resistance between ground and instrument cluster 20-pin harness connector C220a terminal No. 4 (Light Blue wire). See Figure. If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in Light Blue wire between instrument cluster and GEM.
  7. Turn ignition switch to RUN position. If 4X4 indicator remains illuminated, go to step  11. If 4X4 indicator goes out, go to step  10.
  8. Turn ignition switch to LOCK position. Disconnect GEM 22-pin harness connector C201c. Disconnect instrument cluster 20-pin harness connector C220a. Disconnect 4-Wheel Anti-Lock Brake System (4WABS) control module harness connector C155. Turn ignition switch to RUN position. Measure voltage between ground and GEM 22-pin harness connector C201c terminal No. 9 (Light Blue wire). See Fig 1. If voltage does not exist, go to next step. If any voltage exists, repair short to power in Light Blue wire between instrument cluster and GEM.
  9. Using NGS tester, observe GEM PID 4WDHIGH. Toggle GEM active command HIGH LIGHT to ON, then OFF. If PID displays ON-B-, go to next step. If PID does not display ON-B-, go to step  11.
  10. Disconnect all GEM harness connectors. Inspect harness connectors for corrosion and pushed out pins. Connect all GEM harness connectors, ensuring they are connected correctly. Operate system and verify if concern is still present. If concern is still present, replace GEM. See GENERIC ELECTRONIC MODULE/CENTRAL TIMER MODULE  under REMOVAL & INSTALLATION. If concern is not present, system is operating correctly at this time. Clear DTCs and perform self-test.
  11. Disconnect all instrument cluster harness connectors. Inspect harness connectors for corrosion and pushed out pins. Connect all instrument cluster harness connectors, ensuring they are connected correctly. Operate system and verify if concern is still present. If concern is still present, replace instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. If concern is not present, system is operating correctly at this time. Clear DTCs and perform self-test.
Fig 1: Identifying Generic Electronic Module 22-Pin Harness Connector C201c Terminals
G96I29189Courtesy of FORD MOTOR CO.
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