got an 04 hemi, when u put it in to 4wd, is there i light that is supposed to come on on the dash? my 4wd works i was just wondering if theres supposed to be a light. thanks guys.

 

if you have the manual 4x4 yes there is. There are alot of them that the light doesn't luminate. It's very cheap and easy fix. About 10 min and 25.00 and your done.

 

ok great, thanks a lot gordie.

 

The sensor is exposed to all weather conditions. Here in the northeast you have the addition of road salt the sensor failure is common. Just a note of caution, make sure the o-ring is in place.


From the 2004 factory service manual


POSITION SENSOR
DESCRIPTION
The transfer case position sensor is an electronic
device whose output can be interpreted to indicate
the transfer case’s current operating mode. The sensor
consists of a five position, resistive multiplexed
circuit which returns a specific resistance value to
the Powertrain Control Module (PCM) for each transfer
case operating mode. The sensor is located on the
top of the transfer case, just left of the transfer case
centerline and rides against the sector plate roostercomb.
The PCM supplies 5VDC (+/- 0.5V) to the sensor
and monitors the return voltage to determine the
sector plate, and therefore the transfer case, position.
OPERATION
During normal vehicle operation, the Powertrain
Control Module (PCM) monitors the transfer case
position sensor return voltage to determine the operating
mode of the transfer case. Refer to the Operating
Mode Versus Resistance table for the correct
resistance for each position (Fig. 87).

TOOL
21 - 442 TRANSFER CASE - NV241 GENII DR
FRONT OUTPUT SHAFT SEAL (Continued)
OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2H 1124-1243
2 4H 650-719
3 NEUTRAL 389-431
4 4L 199-221
5 NOT USED 57-64
REMOVAL
(1) Raise and support the vehicle.
(2) Disengage the transfer case position sensor
connector from the position sensor.
(3) Remove the position sensor from the transfer
case.
INSTALLATION
(1) Inspect the o-ring seal on the transfer case
position sensor. Replace the o-ring if necessary.
(2) Install the transfer case position sensor into
the transfer case. Torque the sensor to 20-34 N·m
(15-25 ft.lbs.).
(3) Engage the transfer case position sensor connector
to the position sensor.
(4) Lower vehicle.
(5) Verify proper sensor operation.
Fig. 87 Position Sensor Linear Movement
1 - POSITION 1 - 10mm ±0.5mm
2 - POSITION 2 - 12mm ±0.5mm
3 - POSITION 3 - 14mm ±0.5mm
4 - POSITION 4 - 16mm ±0.5mm
5 - POSITION 5 - 18mm ±0.5mm
6 - POSITION 6 - 20mm±0.5mm - FULL EXTENSION