Ford 2000 Ranger Workshop Manual

SECTION 308-07A: Tr ansfer Case — Genera l Information 2000 Ranger Worksho p Manual

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DIAGNOSIS AND TES TING

Transfer Case

Refer to Wiring Diagrams Ce ll 34, Electronic Shift Control for schematic and connector inform ation.

Refer to Wiring Diagrams Ce ll 59, Generic Electronic Module for schematic and connector information.

Special Tool(s)

73III Automotive Meter 105-R0057 or equivalent

Worldwide Diagnostic System (W DS) 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

Procedure revision date: 06/18/1999

Vacuum Pump or equivalent 014-R1054

Vacuum Test Cap or equivalent 205-401

Pulse Vacuum Hublock Vacuum Schematic

Wiring harness

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Inspection and Verification

1. NOTE: The GEM/CTM must be reconfigured upon replacement. Refer to the scan tool help s creen on the configuration card to program the tire size and axle ratio.

The transfer case is a generic electronic module (GEM) controlled system.

2. Verify the customer concern by operating the 4X4 system.

3. Visually inspect for obvious signs of mechanical and electrical damage.

Visual Inspection Chart

Mechanical Electrical



Switch(es)

4. If the concern remains after the inspection connect the scan too l to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle:



5. If the scan tool still does not communicate with the vehicle, re fer to the scan tool manual.

6. Perform the DATA LINK DIAGN OSTIC TEST. If the scan tool responds with:



7. If the DTCs retrieved are related to the concern, go to GEM/CTM Diagnostic Trouble Code (DT C) Index to continue diagnostics.

8. If no DTCs related to the concern are retrieved, proceed to Sym ptom Chart to continue diagno stics.

GEM/CTM Diagnostic Trouble Code (DTC) Index

GEM/CTM Diagnostic Troubl e Code (DTC) Index

DTC Description

B1302 Accessory Delay Relay Coil C ircuit

Failure



Fuse(s)



Connections



Lamps



Circuitry

check that the program card is properly installed. check the connections to the vehicle. check the ignition switch position.

CKT914, CKT915 or CKT70 =ALL ECUS NO RESP/NOT EQUI P, refer to Section 418-00. NO RESP/NOT EQUIP for GEM/CTM, go to Pinpoint Test D. SYSTEM PASSED, retrieve and record the continuous diagno stic trouble codes (DTCs), era se the continuous DTCs and perf orm self-test diagnostics for the GEM/CTM.

DTC

Caused By Action

GEM REFER to Section 501-11.

B1304 Accessory Delay Relay Coil C ircuit

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Short to Battery

B1313 Battery Saver Relay Coil — Circuit

Failure

B1315 Battery Saver Relay Coil Circ uit

Short to Battery

B1317 Battery Voltage HIGH GEM/CTM REFER to Section 414-00.

B1318 Battery Voltage Low GEM/CTM REFER to Section 414-00.

B1322 Driver Door Ajar Circuit Short to

Ground

B1323 Door Ajar Lamp Circuit Failure GEM/CTM REFER to Section 413-01.

B1325 Door Ajar Lamp Circuit Short to

Battery

B1330 Passenger Door Ajar Short to

Ground

B1340 Chime Input Request Short to

Ground

B1342 GEM/CTM is Defective GEM/CTM CLEAR the DTCs. RETRIEVE the DTCs. If DTC B1342 is retrie ved, REPLACE the GEM/CTM ; REFER to Section 419-10.

B1352 Ignition Key-In Circuit Fai lure GEM/CTM REFER to Section 413-09.

B1355 Ignition RUN Circuit Failure GEM/CTM REFER to Section 211-05.

B1359 Ignition RUN/ACC Circuit Failu re GEM/CTM REFER to Section 211-05.

B1371 Illuminated Entry Relay Circui t

Failure

B1373 Illuminated Entry Relay Short to

Battery

B1398 Power Window driver One-Touch

Window Relay Circuit Failure

B1400 Power Window driver One-Touch

Window Relay Coil Circuit Short to Battery

B1404 Driver Power Window Down Sw itch

Input Open CKT

B1405 Driver Power Window Down Sw itch

Input Short Circuit to Battery

B1410 Driver Power Window Motor C ircuit

Failure

B1426 Seat Belt Lamp Circuit Short to

Battery

B1428 Seat Belt Lamp Circuit Failure GEM/CTM REFER to Section 413-01.

B1431 Wiper Brake/Run Relay — Ci rcuit

Failure

B1432 Wiper Brake/Run Relay — Sho rt to

Battery

B1434 Wiper Hi/Lo Speed Relay — Circuit

Failure

B1436 Wiper Hi/Lo Speed Relay Circ uit

Short to Battery

B1438 Wiper Mode Select Switch Circu it

Failure

B1441 Wiper Mode Select Switch Short to

Ground

B1446 Wiper Park Sense Circuit Failu re GEM/CTM REFER to Section 501-16.

B1450 Wiper/Wash Interval Delay Swit ch

Input Circuit Failure

B1453 Wiper/Wash Interval Delay Swit ch

Input Short to Ground

B1458 Wiper/Washer Pump Motor Re lay

Circuit Failure

B1460 Wiper/Washer Pump Motor Re lay

Coil Short to Battery

B1462 Seat Belt Switch Circuit Failure GEM/CTM REFER to Section 413-09.

B1466 Wiper Hi/Low Speed Not Switching GEM/CTM REFER to Section 501-16.

B1467 Wiper Hi/Low Speed Circuit Mot or

Short to Battery

B1473 Wiper Low Speed Circuit Motor

Failure

B1475 Accessory Delayed Relay Contacts

Short to Battery

B1476 Wiper High Speed Circuit Motor

Failure

B1483 Brake Pedal Input Circuit Failure GEM GO to Pinpoint Test B.

B1485 Brake Pedal Input Short Circuit to

Battery

B1577 Park Lamp Input Circuit Short to

Battery

B1610 Illuminated Entry Input (From RAP

Module) Circuit Short to Ground

GEM REFER to Section 501-11.

GEM/CTM REFER to Section 417-02.

GEM/CTM REFER to Section 413-01.

GEM/CTM REFER to Section 417-02.

GEM/CTM REFER to Section 413-09.

TEST the system for normal opera tion.

GEM/CTM REFER to Section 417-02.

GEM REFER to Section 501-11.

GEM/CTM REFER to Section 413-01.

GEM/CTM REFER to Section 501-16.

GEM REFER to Section 501-11.

GEM/CTM Section 501-16.

GEM GO to Pinpoint Test B.

GEM/CTM REFER to Section 413-09.

GEM/CTM REFER to Section 417-02.

B1840 Wiper Power Circuit Failure GEM/CTM REFER to Section 501-16.

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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 config uration

C1751 VSS Output Short to Battery GEM/CTM REFER to Section 310-03or REF ER to Section 413-01.

C1752 VSS Output Short to Ground GEM/CTM REFER to Section 310-03or REF ER to Section 413-01.

P0500 Vehicle Speed Signal Circuit Fai lure GEM GO to Pinpoint Test B.

P1804 4WD High Indicator Circuit Fai lure GEM GO to Pinpoint Test C.

P1806 4WD High Indicator Short to Battery GEM GO to Pinpoint Test C .

P1808 4WD Low Indicator Circuit Fail ure GEM GO to Pinpoint Test C.

P1810 4WD Low Indicator Short to Pow er GEM GO to Pinpoint Test C.

P1812 4WD Mode Select Switch Circui t

Failure

P1815 4WD Mode Select Switch Circui t

Short to Ground

P1820 Transfer Case CW Shift Relay

Circuit — Failure

P1822 Transfer Case CW Shift Relay Co il

Short to Power

P1824 4WD Electric Clutch Relay Cir cuit

Failure

P1826 4WD Low Clutch Relay Short to

Power

P1828 Transfer Case CCW Shift Rela y Coil

Circuit Failure

P1830 Transfer Case CCW Shift Rela y Coil

Short to Battery

P1838 Transfer Case Shift Motor Circui t

Failure

P1846 Transfer Case CONTACT PL ATE

"A" Circuit Failure

P1850 Transfer Case CONTACT PL ATE

"B" Circuit Failure

P1854 Transfer Case CONTACT PL ATE

"C" Circuit Failure

P1858 Transfer Case CONTACT PL ATE

"D" Circuit Failure

P1863 Transfer Case CONTACT PL ATE

Power Circuit Open

P1866 Transfer Case System Concern GEM GO to Pinpoint Test A.

P1867 Transfer Case Contact Plate

General Circuit Failure

P1832 Transfer Case Differential Lock-Up

Solenoid Failure

P1833 Transfer Case Differential Lock-Up

Solenoid Open Circuit

P1834 Transfer Case Differential Lock-Up

Solenoid Short to Battery

P1835 Transfer Case Differential Lock-Up

Solenoid Short to Ground

P1878 Transfer Case Disengage Solenoid

Circuit Failure

P1879 Transfer Case Disengage Solenoid

Open Circuit

P1880 Transfer Case Disengage Solenoid

Short to Battery

P1885 Transfer Case Disengage Solenoid

Short to Ground

P1891 Transfer Case Contact Plate

Ground Return Circuit Open

GEM/CTM Parameter Identifi cation (PID) Index

GEM/CTM Parameter Identification (PID) Index

PID Description Expected Values

VSS_GEM Vehicle Speed Input 0 - 255 KPH

PARK_SW External Access Ajar Switch Status OFF, ON

D_DR_SW Driver Door Ajar Switch Status CLOSED, AJAR

P_DR_SW Passenger Door Ajar Switch Status CLOSED, AJAR

IGN_KEY Key In Ignition Status IN, OUT

IGN_GEM Ignition Switch Status START, RUN, OFF, ACC

BATSAV Battery Saver Relay Circuit ON---, OFF---, ON-B-, OFFO- G

VBATGEM Battery Voltage 0.0 VDC - 14.3 VDC

INTLMP Illuminated Entry Relay Circui t ON-- -, OFF---, ON-B-, OFFO-G

CLTCHSW Transmission Clutch Interlock Switch ENGAGED, NOT ENGAGED

GEM GO to Pinpoint Test A.

GEM GO to Pinpoint Test E.

GEM GO to Pinpoint Test A.

card to program the tire size and axle ratio. TEST the system for normal operation. If DTC B 2141 is still present, REPLACE

the GEM/CTM; REFER to Section 419-10. TEST the system for normal operation.

NTRL_SW Neutral Safety Switch Input NTRL, not NTRL

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MTR_CCW Transmis sion 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-

4WDCLCH 4WD Electronic Clutch Output Status (GEM Only) ON---, OFF---, OFFO-G, ON-B-

4WDLOW 4WD Low Indicator Status (GEM Only) ON---, OFF---, ON-B-, OFFO- G

4WDHIGH 4WD High Indicator Status (GE M Only) ON---, OFF---, ON-B-, OFFO- G

4WD_SW 4WD Switch Status (GEM Only) 2WD, 4WD HIGH, 4WD LOW

PLATE_A Transfer Case Contact Plate Switch A (GEM Only) OPEN, CLOSED

PLATE_B Transfer Case Contact Plate Switch B (GEM Only) OPEN, CLOSED

PLATE_C Transfer Case Contact Plate Switch C (GEM Only) OPEN, CLOSED

PLATE_D Transfer Case Contact Plate Switch D (GEM Only) OPEN, CLOSED

BOO_GEM Brake Pedal Position (BPP) Switc h Input ON, OFF

PLATEPW Contact Plate Ground Output (GEM Only) ON---, OFF---

D_SBELT Driver Seat Belt Status OUT, IN

IPCHIME External Chime Request ON, OFF

SBLTMP Seat Belt Indicator Status OFF, ON, OFFO-G, ON-B-

DRAJR_L Door Ajar Warning Lamp Circuit OFF, ON

D_PWRLY One Touch Down Relay Coil Circuit Status (GEM Only) ON---, OFF---, ON-B-, OFFO-G

Driver Power Window Regulator Electric Drive Current (GEM Only) 0.25 amp increments

PWAMP

D_PWPK Driver Power Win dow Regulator Electric Drive Pe ak Current (GEM Only) 0.25 amp increments

ACCDLY Accessory Delay Relay Coil Circuit (GEM Only) ON---, OFF---, ON-B -, OFFO-G

WPPK_PK Wiper Park-to-Par k Time 0 - 6.5 Seconds

WPMODE Wiper Control Mod e Status WASH, OPEN, INVLD, OFF, INTVL 1-7, LOW, HIGH

WPPRKSW Wiper Motor Status PARKED, notPRK

WPRUN Wiper M ode Run Relay ON---, OFF---, ON-B-, OFFO- G

WPHISP Wiper HI/LO Relay Status ON---, OFF---, ON-B-, OFFO- G

WASH_SW Washer Pump Relay Switch Status ON, OFF, ON-B -, OFFO-G

GEM/CTM Active Command Index

Active Command Display Action

PID LATCH PID LATCH ON, OFF

FRONT WIPER WIPER RLY ON, OFF

FRONT WIPER SPEED RLY ON, OFF

FRONT WIPER WASH RLY ON, OFF

WARNING LAMPS AND CHIME SBLT LAMP ON, OFF

WARNING LAMPS AND CHIME CHIME ON, OFF

WARNING LAMPS AND CHIME AJAR LAMP ON, OFF

BATTERY SAVER BATT SAVR ON, OFF

INTERIOR COURTESY LAMPS INT LAMPS ON, OFF

ONE TOUCH DOWN AND ACCY DELAY (GEM only) ACCY RLY ON, OFF

ONE TOUCH DOWN AND ACCY DELAY (GEM only) ONE TOUCH ON, OFF

4-WHEEL ELECTRONIC SHI FT (GEM only) CW/CCW ON, OFF

4-WHEEL ELECTRONIC SHI FT (GEM only) HIGH LAMP On, OFF

4-WHEEL ELECTRONIC SHI FT (GEM only) LOW LAMP ON, OFF

4-WHEEL ELECTRONIC SHI FT (GEM only) PLAT E PWR ON, OFF

4-WHEEL ELECTRONIC SHI FT (GEM only) SHF T CLCH ON, OFF

SHIFT CLUTCH CONTROL CLUTCH SOL ANALOG %

GEM/CTM Wiggle Test Diagno stic Trouble Code (DTC) Index

GEM/CTM Wiggle Test Diagn ostic Trouble Code (DTC) Index

DTC Description DTC Caused By

B1317 Battery Voltage HIGH G EM/CTM

B1318 Battery Voltage Low GEM/CTM

B1322 Driver Door Ajar Circuit Short to Ground GEM/CTM

B1330 Passenger Door Ajar Short to Groun d GEM/CTM

B1352 Ignition Key-In Circuit Failure GEM/CTM

B1410 Driver Power Window Motor Circuit Failure GEM

B1438 Wiper Mode Select Switch Circuit Failure GEM/CTM

B1441 Wiper Mode Select Switch Short to Gr ound GEM/CTM

B1446 Wiper Park Sense Circuit Failure GEM/CTM

DOOR LOCK CONTROL DD UNLOCK ON, OFF

DTCs and it may exhibit erratic operation after installation.

B1450 Wiper/Wash Interval Delay Switch Input Circuit Failure GEM/CTM

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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 Batt ery GEM/CTM

B1610 Illuminated Entry Input (From RAP Module) Circuit Short to Ground GEM/ CTM

Symptom Chart

Condition Possible Sources Action



The Vehicle Does Not Shift Between 2WD and 4WD Modes Properly



The Vehicle Does Not Shift Between 4WD HIGH and 4WD LOW Modes Properly



The 4x4 HIGH and/or 4x4 LOW Indicator(s) Do/Does Not Operate Properly



No Communication With the Mo dule — GEM/CTM



The Pulse Vacuum Hublocks Do Not Operate Properly (Transfer Case Motor Movement and Front Driveshaft Operate Properly)

Pinpoint Tests



4WD mode switch.



Electric shift relay.



Electronic shift control module.



GEM.



Circuitry.



Transfer case shift motor.



Transfer case electric clutch.



Transfer case mechanism.



DTC B1313.



DTC B1315.



DTC P1812.



DTC P1815.



DTC P1820.



DTC P1822.



DTC P1824.



DTC P1826.



DTC P1828.



DTC P1830.



DTC P1838.



DTC P1846.



DTC P1850.



DTC P1854.



DTC P1858.



DTC P1863.



DTC P1866.



DTC P1867.



DTC P1891.



4WD mode switch.



Neutral safety switch.



Circuitry.



Brake switch.



Electric shift relay.



Electronic shift control module.



Transfer case mechanism.



Transfer case electric clutch.



Digital TR sensor.



Vehicle speed sensor/circuits.



GEM.



DTC P1483.



DTC P1485.



DTC P1812.



DTC P1815.



DTC P0500.



Bulb.



Digital TR sensor.



Circuitry.



DTC P1804.



DTC P1806.



DTC P1808.



DTC P1810.



Fuse.



Circuitry.



GEM/CTM.



Circuitry.



GEM.



PVH solenoid.



Vacuum lines.



Hublock.



Wheel and knuckle.



Wheel hub.



ABS sensor (if equipped).



DTC P1832.



DTC P1833.



DTC P1834.



DTC P1835.



DTC P1878.



DTC P1879.



DTC P1880.



DTC P1885.



GO to Pinpoint

Test A.



GO to Pinpoint

Test B.



GO to Pinpoint

Test C.



GO to Pinpoint

Test D.



GO to Pinpoint

Test E.

CAUTION: Before removing and installing the GEM or its connectors, disconnect the batte ry. Failure to follow this caution will result in GEM storin g many erroneous

CAUTION: Be careful when probing the fuse junction panel, power distribution box or an y connectors. Damage will result to the connector recepta cle if the probe or

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terminal being used is too large.

CAUTION: Electronic module s are sensitive to electrostatic discharges. If exposed to thes e charges, damage may result.

NOTE: If continuous DTCs are recorded and the symptom is not present when performing th e pinpoint tests, an intermittent concern may be the cause. Always check for loose connections

and corroded terminals.

NOTE: Complete the entire pinpoint test related to the symptom before replacing the GEM.

PINPOINT TEST A: THE VEHI CLE DOES NOT SHIFT BETWEEN 2WD AND 4WD MODES PROPERLY

A1 CHECK THE IGNITION S TATES — MONITOR THE GEM PID IGN_GEM

CONDITIONS DETAILS/RESULTS/ACTIO NS

Scan Tool

Monitor the GEM PID IGN_GEM while turning the ignition switch through the RUN, OFF and ACC positions.

A2 RETRIEVE THE DIAGNOST IC TROUBLE CODES (DTCS)

NOTE: DTCs P1838 and P1866 require clearing the GEM keep alive memory (KAM) after repairs have been completed. Scan tool will not clear these codes. The battery must be disconnected and reconnected to clear these DTCs.

Clear Continuous DTCs

GEM On-Demand Self-Test



Do the PID values agree with the ignition switch positions?

Yes

GO to A2.

No REFER to Section 417-02.

Retrieve and document continuous DTCs.



Are any DTCs recorded?

Yes

If DTC B1342, REPLACE the GEM. REFER to Section 419- 10. CLEAR the DTCs. TEST the system for normal operation.

If DTC B1313, GO to A22 .

If DTC B1315, GO to A22 .

If DTC P1812, GO to A5 .

If DTC P1815, GO to A5 .

If DTC P1820, GO to A41 .

If DTC P1822, GO to A41 .

If DTC P1824, GO to A18 .

If DTC P1826, GO to A18 .

If DTC P1828, GO to A41 .

If DTC P1830, GO to A41 .

If DTC P1838, GO to A37 .

If DTC P1846, GO to A58 .

If DTC P1850, GO to A58 .

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If DTC P1854, GO to A58 .

If DTC P1858, GO to A58 .

If DTC P1863, GO to A58 .

If DTC P1866, GO to A58 .

If DTC P1867, GO to A58 .

If DTC P1891, GO to A58 .

A3 CHECK THE 4X4 HIGH L AMP INDICATOR — TRIGGER THE GEM ACTIVE COMMAND HIGH LAMP ON

GO to A3.

Trigger the GEM active command HIGH LAMP ON then OFF.

A4 CHECK THE 4X4 LOW LAMP INDICATOR — TRIGGER THE GEM ACTIVE COMMAND LO W LAMP ON

A5 CHECK THE 4X4 MODE SW ITCH — MONITOR THE GEM PID 4WD_SW IN 2WD POSIT ION



Does the 4x4 HIGH indicator illuminate then go off?

Yes

GO to A4.

No GO to Pinpoint Test C.

Trigger the GEM active command LOW LAMP ON then OFF.



Does the 4x4 LOW indicator illuminate then go off?

Yes

GO to A5.

No GO to Pinpoint Test C.

Monitor the GEM PID 4WD_SW .

Place the mode switch in the 2WD position.



Does the PID indicate 2WD?

Yes

GO to A6.

No GO to A8.

A6 CHECK THE 4X4 MODE SW ITCH — MONITOR THE GEM PID 4WD_SW IN THE 4X4 HI GH POSITION

Place the mode switch in the 4X4 HIGH position.

If the PID indicates OFFO-G, GO to A14 .

Monitor the GEM PID 4WD_SW .

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

Does the PID indicate 4WD HIG H?

Yes

GO to A7.

A7 CHECK THE 4X4 MODE SW ITCH — MONITOR THE GEM PID 4WD_SW

A8 CHECK THE 4X4 MODE SW ITCH IN THE 2WD POSITION

GO to A8.

Monitor the GEM PID 4WD_SW .

Place the mode switch in the 4X4 LOW position.



Does the PID indicate 4WD L OW?

Yes

GO to A16.

No GO to A8.

If the PID indicates OFFO-G, GO to A14 .

4X4 Mode Switch C225

Place the mode switch in the 2WD position.

Measure the resistance between the mode switch terminals 2 and 3.

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

Yes GO to A9.

A9 CHECK THE 4X4 MODE SW ITCH IN THE 4X4 HIGH POSI TION

REPLACE the mode switch. CLEAR the DTCs. TEST the sy stem for normal operation.

Place the mode switch in the 4X4 HIGH position.

Is the resistance between 3700 and 4100 ohms?

A10 CHECK THE 4X4 MODE SWITCH IN THE 4X4 LOW POSI TION

Measure the resistance between the mode switch, terminals 2 and 3.



Yes GO to A10.

No REPLACE the mode switch. CLEAR the DTCs. TEST the sy stem for normal operation.

Place the mode switch in the 4X4 LOW position.

Measure the resistance between the mode switch, terminals 2 and 3.

Is the resistance between 1050 and 1150 ohms?



Is the resistance between 340 and 380 ohms?

Yes

GO to A11.

A11 CHECK CIRCUIT 465 (W/LB) FOR OPEN

REPLACE the mode switch. CLEAR the DTCs. TEST the sy stem for normal operation.

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4X4 Mode Switch C225

GEM C223

A12 CHECK CIRCUIT 465 (W/LB) FOR SHORT TO POWER

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?

Yes

GO to A12.

No REPAIR circuit 465 (W/LB). CLEAR the DTCs. TEST the system for normal operation.

Measure the voltage between mode switch C225-3, circuit 465 (W/LB), and ground.

A13 CHECK CIRCUIT 465 (W/LB) FOR SHORT TO GROUND

A14 CHECK CIRCUIT 359 (GY/ R) FOR OPEN



Is any voltage indicated?

Yes

REPAIR circuit 465 (W/LB). CLEAR the DTCs. TEST the system for normal operation.

No GO to A13.

Measure the resistance between mode switch C225-3, circuit 465 (W/LB), and ground.



Is the resistance greater than 10,000 ohms?

Yes

GO to A14.

No REPAIR circuit 465 (W/LB). CLEAR the DTCs. TEST the system for normal operation.

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4X4 Mode Switch C225

GEM C221

A15 CHECK CIRCUIT 359 (GY/ R) FOR SHORT TO POWER

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?

Yes

GO to A15.

No REPAIR circuit 359 (GY/R). CLEAR the DTCs. TEST the system for normal operation.

Measure the voltage between mode switch C225-2, circuit 359 (GY/R), and ground.

A16 CHECK THE FRONT DR IVESHAFT ENGAGEMENT

A17 CHECK THE FRONT DR IVESHAFT DISENGAGEMENT



Is any voltage indicated?

Yes

REPAIR circuit 359 (GY/R). CLEAR the DTCs. TEST the system for normal operation.

No REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for no rmal operation.

Engage 4X4 HIGH and drive a short distance.

Raise and support the vehicle; refer to Section 100-02.

NOTE: The front and rear driveshafts should both spin.

Observe the front and rear driveshafts.



Does the transfer case lock the front driveshaft to the rear driveshaft?

Yes

GO to A17.

No GO to A41.

If 4WD engagement is prolonged, harsh or noisy, GO to A18 .

When 4X4 is disengaged, the front driveshaft may spin due to viscous drag in the transfer case, especially

A18 CHECK THE CLUTCH RE LAY

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Turn the 4X4 mode switch to the 2WD position.

NOTE:

if cold. If this occurs, the front drive line can easily be stopped.

Drive the vehicle in reverse for 10 feet (3 meters) to disengage the front hubs.



Does only the rear driveshaft spin?

Yes

GO to Pinpoint Test E.

No If the front driveshaft is not working properly, GO to A41 .

A19 CHECK THE CLUTCH RE LAY COIL CIRCUIT — MONITOR THE GEM PID 4WDELCL

A20 CHECK CIRCUIT 275 (Y ) FOR SHORT TO POWER

Check the clutch relay; refer to Component Test.



Is the clutch relay OK?

Yes

RECONNECT the clutch relay. GO to A19 .

No REPLACE the clutch relay. CLEAR the DTCs. TEST the sys tem for normal operation.

Trigger the GEM active command SHIFT CLUTCH to ON.

Monitor the GEM PID 4WDELC L.



Does the GEM PID 4WDELCL display ON---?

Yes

GO to A21.

No If the PID displays ON-B-, GO to A20 .

Clutch Relay

GEM C223

Measure the voltage between clutch relay, connector pin 1, ci rcuit 275 (Y), and ground.

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

Is any voltage indicated?

Yes

REPAIR circuit 275 (Y). CLE AR the DTCs. TEST the system for normal operation.

A21 CHECK THE ELECTRIC S HIFT RELAY COIL CIRCUIT — MONITOR THE GEM PID 4WDELCL

REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for no rmal operation.

Trigger the GEM active command SHIFT CLUTCH to OFF.

Monitor the GEM PID 4WDELC L.

A22 CHECK THE BATTERY SA VER RELAY

A23 CHECK THE BATTERY SA VER RELAY COIL CIRCUIT — MONITOR THE GEM PID BAT T_SAVE

Battery Saver Relay



Does the GEM PID 4WDELCL display OFF--?

Yes

GO to A36.

No If the PID displays OFFO-G, GO to A22 .

Check the battery saver relay; refer to Component Test.



Is the battery saver relay OK?

Yes

GO to A23.

No REPLACE the battery saver relay. CLEAR the DTCs. TEST the system for normal operation.

Trigger the GEM active command BATT_SAVR to ON.

Monitor the GEM PID BATT_SAV R.

A24 CHECK CIRCUIT 1005 (P /O) FOR SHORT TO POWER

Battery Saver Relay

GEMC



Does the GEM PID BATT_SA VR display ON---?

Yes

GO to A25.

No If the GEM PID BATT_SAVR displays ON-B-, GO to A24 .

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A25 CHECK THE BATTERY SA VER RELAY COIL CIRCUIT — MONITOR THE GEM PID BAT T_SAVR

A26 CHECK FOR VOLTAGE TO THE BATTERY SAVER RELAY — CIRCUIT 792 (T/Y)

Measure the voltage between battery saver relay connector pin 2, circuit 1005 (P/O), and grou nd.



Is any voltage indicated?

Yes

REPAIR circuit 1005 (P/O). CLEAR the DTCs. TEST the system for normal operation.

No REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for no rmal operation.

Trigger the GEM active command BATT_SAVR to OFF.

Monitor the GEM PID BATT_SAV R.



Does the GEM PID BATT_SA VR display OFF---?

Yes

GO to A36.

No If the GEM PID BATT_SAVR displays OFFO-G, GO to A26 .

Battery Saver Relay

A27 CHECK THE POWER O UTPUT FROM FUSE JUNCTION PANEL FUSE 26 (10A)

Measure the voltage between fuse 26 (10A) pin 1, and ground; and between fuse 26 (10A) pin 2, and ground.

Measure the voltage between battery saver relay connector pin 1, circuit 792 (T/Y), and groun d; and between battery saver relay connector pin 5, circuit 792 (T/Y), and ground.



Are the voltages greater than 10 volts?

Yes

GO to A32.

No GO to A27.

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A28 CHECK FUSE JUNCTIO N PANEL FUSE 26 (10A)

Fuse 26 (10A)

A29 CHECK CIRCUIT 792 (T/Y ) FOR SHORT TO GROUND

Battery Saver Relay



Are the voltages greater than 10 volts?

Yes

REPAIR open in circuit 792 (T/Y). REPLACE the fuse. CLEAR the DTCs. TEST the system for normal operation.

No GO to A28.



Is the fuse OK?

Yes

REPAIR the fuse junction pa nel. TEST the system for norma l operation.

No GO to A29.

Measure the resistance between battery saver relay connec tor pin 1, circuit 792 (T/Y), and g round; and between battery saver relay connector pin 5, circuit 792 (T/Y), and ground.



Are the resistances greater than 10,000 ohms?

Yes

GO to A30.

A30 CHECK CIRCUIT 705 (LG /O) FOR SHORT TO GROUND

Clutch Relay

J50 Relay

Measure the resistance between battery saver relay connec tor pin 3, circuit 705 (LG/O), and ground.

REPAIR circuit 792 (T/Y). TEST the system for normal operation.

A31 CHECK CIRCUIT 705 (LG /O) FOR OPEN

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A32 CHECK CIRCUIT 275 (Y ) FOR OPEN

GEM C223



Is the resistance greater than 10,000 ohms?

Yes

GO to A31.

No REPAIR circuit 705 (LG/O). TEST the system for normal operation.

Measure the resistance between battery saver relay connec tor pin 3, circuit 705 (LG/O), and clutch relay connector pin 2, circuit 705 (LG/O ).



Is the resistance less than 5 ohms?

Yes

GO to A32.

No REPAIR circuit 705 (LG/O). TEST the system for normal operation.

Measure the resistance between clutch relay connector pin 1, circuit 275 (Y), and GEM C223 -15, circuit 275 (Y).



Is the resistance less than 5 ohms?

Yes

GO to A33.

A33 CHECK CIRCUIT 275 (Y ) FOR SHORT TO GROUND

REPAIR circuit 275 (Y). TES T the system for normal operation.

Measure the resistance between clutch relay connector pin 1, circuit 275 (Y), and ground.

A34 CHECK CIRCUIT 1005 (P /O) FOR SHORT TO GROUND

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A35 CHECK CIRCUIT 1005 (P /O) FOR OPEN



Is the resistance greater than 10,000 ohms?

Yes

GO to A34.

No REPAIR circuit 275 (Y). TES T the system for normal operation.

Measure the resistance between battery saver relay connec tor pin 2, circuit 1005 (P/O), and ground.



Is the resistance greater than 10,000 ohms?

Yes

GO to A35.

No REPAIR circuit 1005 (P/O). TEST the system for normal operation.

Measure the resistance between battery saver relay connec tor pin 2, circuit 1005 (P/O), and GEM C224-8, circuit 1005 (P/O).



Is the resistance less than 5 ohms?

Yes

REPLACE the GEM; REFER to Section 419-10. CLEAR the DTCs. TEST the system for no rmal operation.

A36 CHECK CIRCUIT 779 (B R) FOR VOLTAGE — GEM AC TIVE COMMAND SHIFT CLUTC H ON

Transfer Case Electric Shift Motor C1001

REPAIR circuit 1005 (P/O). TEST the system for normal operation.

Trigger the GEM active command SHIFT CLUTCH to ON.

Measure the voltage between transfer case electric shift motor C1001-8, circuit 779 (BR), a nd ground.

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

Is the voltage greater than 10 volts?

Yes

GO to A37.

A37 CHECK CIRCUIT 779 (B R) FOR VOLTAGE — GEM AC TIVE COMMAND SHIFT CLUTC H OFF

A38 CHECK CIRCUIT 779 (B R) FOR SHORT TO POWER

GO to A38.

Trigger the GEM active command SHIFT CLUTCH to OFF.

Measure the voltage between transfer case electric shift motor C1001-8, circuit 779 (BR), a nd ground.



Is the voltage zero volts?

Yes

REPLACE the clutch relay. CLEAR the DTCs. TEST the sys tem for normal operation.

No GO to A38.

Clutch Relay

A39 CHECK THE CLUTCH RE LAY SWITCHING CIRCUIT

Measure the voltage between the clutch relay connector pin 3, circuit 779 (BR), and ground.



Is any voltage indicated?

Yes

REPAIR circuit 779 (BR). CLEA R the DTCs. TEST the system for normal operation.

No GO to A39.

Measure the voltage between clutch relay connector pin 5, c ircuit 704 (DG/LG), and ground.

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Ford 2000 Ranger Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual