I have had my Service 4WD light come on 2001 4.7. It is stuck in 4HI and won't come out. The lights were all out, which searching said it could be the TCCM but they have come back on and the 4HI light is lit.

I can hear the motor trying to switch when I turn the key on. It will light the 2WD light and switch back to 4HI three times and the Service 4WD light will come back on.

I borrowed a better code reader that allows me to read info for the transfer case. The error comes up as "Encoder Error". Another search was done for this and it seems the error is caused by the encoder on the shift motor.

I bought a new motor, took the drive shaft off but can't remove the transfer case companion flange. The torque for the nut says 80 ft/lb when tightening but it is STUCK. I was lucky to have the 30mm socket but tried a 1/2 inch breaker bar and the impact driver for lug nuts and still can't get it loose.

I don't have a torch yet, but would heating the nut possibly help the situation I find myself in? I ended up putting the drive shaft back on until I can find a way to take the nut off.

 

seems to me like the sensor in the shift motor, i believe they are sold as one unit, your best bet for getting the nut off is pb blaster/nut buster/wd-40 and a big *** breaker bar and some pip and just hang on it till it breaks free

 

+2 you need something like PB blaster to help it along... If its extremely cold (below 32 degrees) be careful putting a whole lot of pressure on it or you may snap the nut then, your in a whole new level of SCREWED.

 

Will the local auto parts store carry PB Blaster? How long does it need to sit to be effective?

We are expecting weather that will keep temps at or below freezing this coming week with some snow. With the weather, being in 4HI isn't as much of a problem as on dry roads.

I have thought of taking it to the mechanic I use to have them break the nut loose. If I did that what would be a reasonable price if all they had to do was break it free if I take the driveshaft back off?

 

PB blaster can be found at any auto or hardware store.. even walmart sells it IIRC...

As for a mechanic breaking it free there all gonna tell ya that it depends on how much effort they have to put into it to get the job done.

 

honestly your best bet is some patience, a BFW a long piece of pipe and a BFH and just work on it itll it breaks loose (breaks meaning the corrosion thats holding it, not the bolt hopefully)

if you lived nearby id offer to give you a hand for a case of beer but your most of the way across the country from me.

 

I'm in Denver, I'd be happy to help, but not sure if I would be any help.

 

Thanks for the offers of help. I will wait till the weather clears up and get after this again. I will also look into getting the PB Blaster and use it prior to the next bump my head, skin my knuckles session.

 

I bought the PB Blaster, sprayed the flange nut and used my impact wrench again and was able to get the nut off. The old motor was removed and new one installed. The Service 4WD light is out and I am able to shift the transfer case through all modes.

Thanks for the tip of using PB Blaster!!

 

Just wanting to know if its a must to take out the front driveshaft in order to get the shift motor out as I have to replace mine on my 01