I'll post some diagrams, - JMC can do the typing lol.



Here's one ^^^

 

Ok thanks JMC...my frustration made me misread! LOL---DirtySCREW

 

Jbrew---that's what I did to test the actuator motor. At first I could not get the actuator arm to move...but I finally got it moving and lubed it up per your recommendations--DirtySCREW

 

Alright, since I have this open, see the blue section links in the diagram above ? Which one do you want to see ?

 

Could you post both the Section 205-03 and the Section 308-07A?? --DirtySCREW

 

Well, going to both of those, I get a list, so that's no good. You need to catch up. JMC wants you to check it from the top, @ the line. So start their, if you haven't yet.

 

ok, will do-----DirtySCREW

 

I like testing the actual part first myself (actuator) , then the lines. To test the lines you have to cap one end of course. Your vac tool should of came with caps and plugs to do this.

 

Ok, here's where I'm at.....help me get further with my diagnosis:

I checked the Vac lines going to each solenoid at the firewall. Both have suction: although the bottom line of each one was the one with suction...don't know if thats good or bad.

I took the cover off the actuator and felt for VAC on the lines after unplugging them from the actuator with the truck cranked. Someone said Ford's diagram is backwards....well mine is how Ford has it. The BLUE line (which engages 4wd) DOES NOT have suction by the actuator. The PINK line HAS suction. What now?

I hooked up my VAC gauge and did the above procedure that Jbrew was so nice to post a pic of. I've got mixed results with it. When I hooked up a line to the nipple on the actuator that the BLUE line came out of....I pumped up 20 inches mercury...and it held....for a little while. After about 2 minutes or so, you could tell that there was an ever so slight drop. When I hooked up to the nipple on the actuator where the PINK line came from...it automatically started dropping and would not hold any VAC.
Something that concerns me is in the above posted pic, it talks about spinning the axle and watching the other axle to see if it rotates. Sometimes it did rotate the other wheel slightly and other times not. I hope this aint saying my shift fork's bad.

That's where I'm at guys....where to now??----DirtySCREW

 

So how do you know it's like Ford has it ? You have the Ford Service Manual, because anything other wouldn't necessarily be Ford. I mean what you have may be right and that is why I've posted what goes where on the page before. You haven' t confirmed.
__________________________________________

Also, testing the part (actuator). Test at the actuator to confirm operation. I'm not sure what's so hard to understand, but I don't think you've pulled that off yet, - not from what I've read anyway. I'll try to locate some shots of when I serviced mine, maybe it will help.

Crap, I have to re-size them first

As you pump, one port engages (4x4) the lever, the other (2wd) disengages. Notice lever positions in pics.




Yea, you shouldn't have to pump it up that much. -



So again, confirm this operation first, in order to move on.

 

If what your saying is that you have confirmed this and the lever isn't moving, then yes, the actuator is bad,- if the rod is free. I haven't had to change one out yet, but have heard that they can be PITA to do, successfully. I mean, -without breaking the bracket.

 

Jbrew--what I was saying IS: I've read where member of this forum AND others have said that Ford has the color of the VAC lines labeled wrong. They say the BLUE line goes to 2wd and PINK line goes to 4wd solenoids. My truck is how ford has it labeled:



And I described me testing the Actuator. Maybe my wording wasn't clear...sorry.

Anyways...TRUCK IS FIXED!!!!!!!!!!!!!!!!!!!!!!!!!! WAHOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOO!!!!!! :b ows:

It was my 4wd Solenoid. I replaced it, jacked the truck up on 4 jack stands, cranked the truck , put in Drive, selected 4wd and the front axles were moving. Got her down and went to a gravel road, selected 4wd, turned the wheel all the way right, leaned out the window as I gave her some gas..and yep...she's working!

I found a crack in the old solenoid!





Anyways, A BIG THANKS TO EVERYONE FOR THEIR HELP!!!!!!!!!!!!!
It's a great relief to have my 4x4 back!
I'll be starting another thread soon, compiling the information and troubleshooting tips with part numbers to help others that come across this problem. Thanks again guys----DirtySCREW

 

AWESOME! Glad it wasn't more serious.. Yes, make sure you you mention that about the Vacuum lines, if you do a write up or whatever. Mine are the opposite of that diagram. Ford must have switched them BACK around at some point, but I'm not sure when that happened. Glad you searched that out, - so you don't think I'm crazy, - well, not so much anyway lol.

BTW - I've never seen the solenoid crack like that. Looks like corrosion or moisture maybe ?

 

Thanks Jbrew....now one more question for ya.

Is replacing this:




just an unbolt/bolt process....or is there more involved. I've gotta replace my passenger one as its throwing grease everywhere----DirtySCREW

 

Iduno, haven't done one yet, but yea once they loose their grease they go to hell.

All I can do is send you the change out procedure from service.