Been lurking since I bought my truck about a month ago. Many of my questions have been answered here already, thank you. But I have one now that I could not find here.

So let me start with... 04 Hemi std cab 4x4 with the floor lever

My question is, 4WD works just fine, but the dash light does not come on? Is it a fuse? bulb? what? All other dash lights seem to work.

Thanks in advance. Hopefully its something simple.

 

The switch on the transfer case is most likely bad. Its about 35$ from the stealership.

 

Hold in the trip odometer button and turn the key to the on / run position (but don't start it) let go of the button and the entire instrument cluster will go thru a self test. The gauge needles will make several sweeps and all of the lights are supposed to come on... I say supposed to, but when I do that on my truck the "low washer fluid" and the "service 4x4" lights do not light up. But when it's out of washer fluid the indicator comes on and the 4x4 light works as it should.

Hmm, well now that didn't really seem helpful, but at least you can do the IC test, maybe yours will work better than mine does.

Otherwise it could be that switch Toefur mentioned.

 

If the transfer case switch is bad the "4WD" light will not light up on the dash during the test.

 

From what I read in the service manual, I think that the "service 4x4" warning indicator is only used for the electronic shifter models, for trucks with the floor shifter that indicator is programmed off. So that explains why it doesn't light up on mine.

I'm not positive, but I was under the impression that the IC self test was a stand alone test to verify all the components internal to the IC worked, regardless of any faulty components that provide input to it.

 

I did said test, and neither the "service" light or "4WD" light right next to it lit up.
Is this switch easy to replace? I have not been under the truck recently to look... It has been raining here the last 3 days, and I have no garage.
What else does this switch control? Anything? Or does it just turn the 4WD light on?
Like I said, I know the 4WD is working (when it is dry, and in 4WD it "barks" when turning tight) would just like the light to be on again with winter coming up, just for the comfort factor.

 

Could be the bulb.
I know with 2nd gens, if the switch on the t-case is bad, or the vacuum actuator at the axle is bad, the light will not come on and only the left side wheel gets power.
But thats my truck and it has SFA, not IFS.

 

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

 

hey guys i have a 99 ram 4x4 and the 4wd light will not light up upon engaging the 4x4 and i have checked the bulb and didnt see that there was a fuse for that so what do you guys think?

 

9 of 10 times on a third gen shift on the fly manual transfer case Its the switch, two minute job with a 18mm wrench if I recall properly.