1998 Expedition/Navigator Workshop Manual

Transcription

1 Page 1 of 64 SECTION A: Transfer Case General Information DIAGNOSIS AND TESTING Procedure revision date: 05/06/2002 Transfer Case Refer to Wiring Diagrams Cell 34 (Expedition, Navigator), All-Wheel Drive for schematic and connector information. Refer to Wiring Diagrams Cell 59 (Expedition, Navigator), Generic Electronic Module for schematic and connector information. Special Tool(s) Digital Multimeter 418-F082 (105-R0005)1 or equivalent New Generation STAR (NGS) Tester 418-F048 ( ) or equivalent Vacuum Pump 416-D001 (D83L-7059-A) or equivalent A4WD Vacuum Schematic A4WD Vacuum Schematic Table 1 4WD Mode Switch Input Resistances Mode Switch Position Resistance (Ohms) 2WD A4WD WD HIGH WD LOW Table 2 4x4 Shift Motor Relay Outputs

2 Page 2 of 64 HI-to-LO LO-to-HI Mode GROUND B+ 4 HIGH to 4 LOW B+ GROUND 4 LOW to 4 HIGH GROUND GROUND Brake Motor Table 3 Neutral Safety Switch Input Conditions Transmission State Start/Clutch Depressed Input Transmission Range Sensor Input In Gear Open Open Park Ground Open Neutral Ground Ground (Start) Park Battery Voltage Open (Start) Neutral Battery Voltage Ground Table 4 Contact Plate Sensor Position Codes Contact Plate Code Left Mech.Stop Left Stop A4WD/2H 2H E * 4H E 4H 4L E * 4L Right Mech.Stop A Closed Closed Closed Closed Closed Open Open Open Closed B Open Open Open Closed Closed Closed Closed Closed Closed C Open Closed Closed Closed Closed Closed Closed Open Open D Open Open Closed Closed Open Open Closed Closed Closed * Refers to the code at the point of transition between two positions or areas of the sensor. * Refers to the code at the point of transition between two positions or areas of the sensor. Inspection and Verification 1. Verify the customer concern by operating the 2WD/4WD engagement. 2. Visually inspect for obvious signs of mechanical, electrical and vacuum damage; refer to the following chart: Visual Inspection Chart Mechanical Switch(es) Vacuum leaks Electrical Fuse(s) Damaged wiring harness Loose or corroded connector(s) Circuitry 3. If the concern remains after the inspection connect the New Generation STAR (NGS) Tester to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: Check that the program card is properly installed. Check the connections to the vehicle. Check the ignition switch position. 4. If the NGS still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: CKT 914, CKT 915 OR CKT 70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section NO RESP/NOT EQUIP for Generic Electronic Module (GEM), go to Pinpoint Test E. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics. GEM Diagnostic Trouble Code (DTC) Index GEM Diagnostic Trouble Code (DTC) Index DTC Test Mode Description Section B1214 B1215 Running board lamp relay coil open or short to ground. REFER to Section Running board lamp relay coil short to power. REFER to Section B1240 Continuous Rear washer pump relay coil open or short to ground. REFER to Section B1241 Continuous Rear washer pump relay coil short to power. REFER to Section B1302 B1304 B1313 B1315 Accessory delay relay coil open or short to ground. (Only set if battery saver relay has no faults.) REFER to Section Accessory delay relay coil short to power. REFER to Section Battery saver relay coil open or short to ground. REFER to Section Battery saver relay coil short to power. REFER to Section B1317 Battery voltage HIGH, greater than 18.0 volts. REFER to Section

3 Page 3 of 64 B1318 Battery voltage LOW, less than 10 volts. REFER to Section B1322 On- LF door open warning circuit short to ground, or door open. REFER to Section B1323 B1325 Door open warning lamp open or short to ground. REFER to Section Door open warning lamp short to power. REFER to Section B1330 On- RF door open warning circuit short to ground, or door open. REFER to Section B1334 On- Liftgate or liftgate glass door open warning circuit short to ground, or door open. REFER to Section B1338 On- RR door open warning circuit short to ground, or door open. REFER to Section B1342 B1345 B1347 B1349 B1352 ECU is defective, RAM/ROM checksum failure. REPLACE the GEM. REFER to Section Heated backlite input circuit short to ground. REFER to Section Heated grid relay coil circuit open or short to ground. REFER to Section Heated grid relay coil short to battery. REFER to Section Key-in-ignition circuit open. REFER to Section B1355 On- Ignition RUN circuit open. REFER to Section B1359 B1365 B1371 B1373 B1398 B1400 Ignition RUN/ACC circuit open. REFER to Section Ignition START circuit short to power. REFER to Symptom Chart for customer concern. Interior lamp relay coil open or short to ground. REFER to Section Interior lamp relay coil short to power. REFER to Section LF one-touch down power window relay coil open or short to ground. REFER to Section LF one-touch down power window relay coil short to power. REFER to Section B1405 On- LF power window switch down circuit short to power. REFER to Section B1408 On- LF power window switch up circuit short to power. REFER to Section B1410 B1426 B1428 LF power window motor excessive current draw. REFER to Section Seat belt lamp circuit short to power. REFER to Section Seat belt lamp circuit open or short to ground. REFER to Section B1431 Continuous Front wiper RUN/PARK relay coil circuit open or short to ground. REFER to Section B1432 Continuous Front wiper RUN/PARK relay coil circuit short to power. REFER to Section B1434 Continuous Front wiper HI/LO speed relay coil circuit open or short to ground. REFER to Section B1436 Continuous Front wiper HI/LO speed relay coil circuit short to power. REFER to Section B1438 Front wiper mode select switch open or short to power. REFER to Section B1441 On- Front wiper mode select switch circuit short to ground. REFER to Section B1445 On- Door handle switch circuit short to ground or handle. REFER to Section B1446 Continuous Front wiper motor PARK sense circuit short to ground. REFER to Section B1450 Front wiper interval delay switch circuit open or short to power. REFER to Section B1453 Continuous Front wiper interval delay switch circuit short to ground for greater than 20 seconds. REFER to Section B1453 On- Wiper interval delay switch circuit short to ground. REFER to Section B1454 Low washer fluid warning indicator output circuit open or short to ground. REFER to Section B1456 On- Low washer fluid warning indicator output circuit short to power. REFER to Section B1458 Continuous Front washer pump motor relay coil circuit open or short to ground. REFER to Section B1460 Continuous Front washer pump motor relay coil short to power. REFER to Section B1462 On- Seat belt switch open circuit. REFER to Section B1466 On- Front wiper HI/LO speed not switching. REFER to Section B1467 Continuous Front wiper HI/LO speed motor circuit short to power. REFER to Section B1473 On- Front wiper LO speed motor circuit failure (wiper energized and park sense not seen). B1475 REFER to Section Delayed accessory relay contacts short to power. REFER to Section B1476 On- Front wiper HI speed motor circuit failure (wiper energized and park sense not seen). REFER to Section B1483 Continuous Brake pedal input open circuit. ( brake input seen for 8 ignition cycles.) GO to Pinpoint Test C. B1485 Continuous Brake pedal input circuit short to battery. GO to Pinpoint Test C. B1574 On- LR door open warning circuit short to ground or door open. REFER to Section B1577 On- Headlamp/parking lamp input circuit short to power. REFER to Section B1610 On- Illuminated entry input short to ground. REFER to Section B1611 Rear wiper mode select switch circuit open or short to battery. REFER to Section

4 Page 4 of 64 B1614 On- Rear wiper mode select switch circuit short to ground. REFER to Section B1814 Rear wiper DOWN relay coil open or short to ground. REFER to Section B1816 Continuous Rear wiper DOWN relay coil short to power. REFER to Section B1818 Rear wiper UP relay coil open or short to ground. REFER to Section B1820 Continuous Rear wiper UP relay coil short to power. REFER to Section B1839 Continuous Rear wiper motor circuit failure. (Relays have no faults and no motor movement detected.) REFER to Section B1840 Continuous Front wiper power circuit failure. REFER to Section C1107 Continuous ABS active fault (ABS event exceeding 2 minutes detected). GO to Pinpoint Test A. P0500 Continuous Vehicle speed signal not detected for 21 ignition START cycles. REFER to Section REFER to Symptom Chart for customer concern. P1804 P1806 P1808 P1810 P1812 P Wheel drive HI indicator open or short to ground. REFER to Section Wheel drive HI indicator short to power. REFER to Section Wheel drive LO indicator open or short to ground. REFER to Section Wheel drive LO indicator short to power. REFER to Section Wheel drive mode select switch open or short to power. 4-Wheel drive mode select switch circuit short to ground. REFER to Symptom Chart for customer concern. REFER to Symptom Chart for customer concern. B1819 On- Neutral safety switch input short to ground. REFER to Symptom Chart for customer concern. P1820 Transfer case LO to HI shift relay coil open or short to ground. P1822 Continuous Transfer case LO to HI shift relay coil short to power. GO to Pinpoint Test B. P Wheel drive electric clutch relay open or short to ground. GO to Pinpoint Test A. P1826 Continuous 4-Wheel drive electric clutch relay short to power. GO to Pinpoint Test A. P1828 Transfer case HI to LO shift relay open or short to ground. GO to Pinpoint Test B. P1830 Continuous Transfer case HI to LO shift relay short to power. GO to Pinpoint Test B. P1832 Continuous Front axle 4-wheel drive solenoid open or short to ground. GO to Pinpoint Test D. P1834 Front axle 4-wheel drive solenoid short to power. GO to Pinpoint Test D. P1836 Continuous Transfer case front shaft speed sensor not detected or not within range. GO to Pinpoint Test A. P1837 Continuous Transfer case rear shaft speed sensor not detected or not within range. GO to Pinpoint Test A. REFER to Symptom Chart for customer concern. P1838 Continuous Transfer case shift motor fails to move. (Energized relays, motor does not move.) REFER to Symptom Chart for customer concern. P1846 Continuous Transfer case contact plate A open circuit. REFER to Symptom Chart for customer concern. P1850 Continuous Transfer case contact plate B open circuit. REFER to Symptom Chart for customer concern. P1854 Continuous Transfer case contact plate C open circuit. REFER to Symptom Chart for customer concern. P1858 Continuous Transfer case contact plate D open circuit. REFER to Symptom Chart for customer concern. P1866 Continuous Transfer case system concern, contact plate failure. REFER to Symptom Chart for customer concern. P1867 Continuous Transfer case contact plate open or short to ground. REFER to Symptom Chart for customer concern. P1868 P1869 Automatic 4-wheel drive indicator circuit open or short to ground. REFER to Section Automatic 4-wheel drive indicator circuit short to power. REFER to Section P1874 On- Hall effect sensor power short to ground. GO to Pinpoint Test A. P1875 On- Hall effect sensor power short to power. REFER to Symptom Chart for customer concern. P1876 P1877 Transfer case 2-wheel drive solenoid open or short to ground. GO to Pinpoint Test D. Transfer case 2-wheel drive solenoid short to power. GO to Pinpoint Test D. P1886 Continuous 4x4 initialization failure (front driveline did not synchronize to rear). GO to Pinpoint Test A. P1891 Transfer case contact plate ground return open circuit. REFER to Symptom Chart for customer concern. GEM Parameter Identification (PID) Reference Chart GEM Parameter Identification (PID) Reference Chart PID Circuit Circuit Description Expected Values BATSAV Fuse Junction Panel (Internal) Battery Saver Relay Circuit ON---, OFF---, ON-B-, OFFO-G BOO_GEM 210 (LB) Brake Pedal Position (BPP) Switch Input ON, OFF CLTCHSW Clutch Pedal Position Switch ENGAGD, notegd DRAJAR 433 (DG/O) Door Ajar Indicator Circuit ON ---, OFF ---, ON-B-, OFFO-G D_DR_SW 344 (BK/Y) LH Door Open Warning Lamp Switch AJAR, CLOSED D_SBELT 85 (BR/LB) LH Safety Belt ON, OFF HALLPWR 774 (LG) Hall Effect Speed Sensor Power ON---, OFF---, ON-B-, OFFO-G ILLE_SW 1013 (BR/LG) Illuminated Entry Input (From RAP Module) ON, OFF

5 Page 5 of 64 IGN_GEM 297 (BK/LG), 1040 (R/LB), 32 (R/LB), 687 (GY/Y) Ignition Switch States START, RUN, OFF, ACC IGN_KEY 158 (BK/PK) Ignition Key-In/Out IN, OUT INTLMP 402 (O/LG) Fuse Junction Panel (Internal) Interior Lamp Relay Circuit ON---, OFF---, ON-B-, ON O-G LGATE_SW 700 (W/PK) Liftgate/Glass Switch Status AJAR, CLOSED LRDR_SW 363 (BK/LB) LR Door Open Warning Lamp Switch AJAR, CLOSED MTR_CCW 781 (O/LB) HI to LO Shift Relay Coil Status ON---, OFF---, ON-B-, OFFO-G MTR_CW 782 (BR/W) LO to HI Shift Relay Coil Status ON---, OFF---, ON-B-, OFFO-G NTRL_SW 463 (R/W) Transmission Range Sensor Input NTRL, not NTRL P_DR_SW 345 (BK/PK) RH Door Open Warning Lamp Switch AJAR, CLOSED PARK_SW 257 (W/R) Headlamp Control Input Switch ON - OFF PLATE_A 771 (P/Y) Transfer Case Contact Plate Switch A OPEN, CLOSED PLATE_B 770 (W) Transfer Case Contact Plate Switch B OPEN, CLOSED PLATE_C 764 (BR/W) Transfer Case Contact Plate Switch C OPEN, CLOSED PLATE_D 763 (O/W) Transfer Case Contact Plate Switch D OPEN, CLOSED PLATEPW 762 (Y/W) Contact Plate Ground Output ON---, OFF---, ON-B-, OFFO-G PWR_RLY 239 (W/O) ABS Active Input (A4WD Only) ON, OFF R_WP_DN 592 (T) Rear Wiper DOWN Relay Status ON---, OFF---, ON-B-, OFF O-G R_WP_MD 485 (PK/BK) Rear Wiper Mode Switch Status LOW, HIGH, WASH, OFF R_WP_PK 587 (P/Y) Rear Wiper Park Sense PARK, notprk R_WP_SW 488 (DG) Rear Washer Relay Output ON---, OFF---, ON-B-, OFFO-G R_WP_UP 591 (LG) Rear Wiper UP Relay Status ON---,OFF---, ON-B-, OFFO-G RB_LMP 1008 (LG/O) Running Board Lamp Output Status OFF---, ON---, OFFO-G, ON-B- RRDR_SW 346 (BK/W) RR Door Open Warning Lamp Switch AJAR, CLOSED SBLTLMP 450 (DG/LG) Safety Belt Warning Indicator ON ---, OFF ---, ON-B-, OFFO-G SPEEDWP N/A Speed Dependent Wiper Function ACTIVE, notact TRA_FSP 435 (Y/LB) Front Shaft Speed KPH TRA_RSP 772 (LB) Rear Shaft Speed KPH VSS_GEM 676 (PK/O), 679 (GY/BK) Vehicle Speed Sensor KPH WASH_SW 686 (T/R) Front Washer Relay Output ON---, OFF---, ON-B-, OFFO-G WFL_LMP 82 (PK/Y) Low Washer Fluid Warning Indicator Circuit ON---, OFF---, ON-B-, OFFO-G WFLUID 81 (R/LG) Low Washer Fluid Switch LOW, OK WPHISP 647 (GY/LB) Front Wiper HI/LO Relay Status ON---, OFF---, ON-B-, OFFO-G WPMODE 680 (LB/O), 684 (PK/Y) Front Wiper/Washer Switch Status WASH, OPEN, INVLD, OFF, INTVL1-7, LOW, HIGH WPPK_PK N/A Front Wiper Park to Park Time 0 to 65 seconds WPPRKSW 671 (LB) Front Wiper Motor Switch Status PARKED, not PRK WPRUN 646 (Y/W) Front Windshield Wiper Run/Park Relay Status ON---, OFF---, ON- B-, OFFO-G 2WDSOL 145 (GY/BK) 2WD Solenoid Status ON---, OFF---, ON-B-, OFFO-G 4WD_LMP 994 (W) A4WD Indicator Status ON---, OFF---, ON-B-, OFFO-G 4WDCLST 976 (O) Four Wheel Drive Clutch Relay Control ON---, OFF---, ON-B-, OFFO-G 4WDHIGH 777 (Y) 4WD High Indicator Status ON---, OFF---, ON-B-, OFFO-G 4WDLOW 778 (O) 4WD Low Indicator Status ON---, OFF---, ON-B-, OFFO-G 4WDSGEM 780 (DB) 4WD Mode INVLD, A42D, 2WD, 4WDLOW, 4WDHIGH, OFFO-G 4WDSOL 605 (R) 4WD Solenoid Status ON---, OFF---, ON-B-, OFFO-G Symptom Chart Symptom Chart Condition Possible Sources Action The A4WD Indicator Flashes When the A4WD Mode Is Selected The Vehicle Does t Shift Between 2WD/A4WD and 4WD Modes Properly The Vehicle Does t Shift Between 4WD HIGH and 4WD LOW Modes Properly The Front Axle Is t Engaging Properly (Transfer Case Motor Movement OK) A4WD clutch relay/circuit. Hall effect speed sensors/circuits. Transfer case electric clutch. 4WABS module/circuit. GEM. A4WD mode switch/circuit. A4WD clutch relay/circuit. Contact plate sensors A, B, C and/or D circuits. Transfer case shift motor/circuit. Transfer case shift relays. Transfer case mechanism. GEM. A4WD mode switch/circuit. VSS. BPP switch. Transfer case shift relays. Transfer case mechanism. Transmission range sensor. GEM. Digital transmission range (DTR) sensor. 4x4 solenoid/circuit. 4x2 solenoid/circuit. Vacuum motor. Vacuum lines. Front differential mechanism. GO to Pinpoint Test A. GO to Pinpoint Test B. GO to Pinpoint Test C. GO to Pinpoint Test D.

6 Page 6 of 64 Communication With the Module GEM GEM. Fuses. Circuitry. GEM. GO to Pinpoint Test E. Pinpoint Tests PINPOINT TEST A: A4WD INDICATOR FLASHES WHEN THE A4WD MODE IS SELECTED NOTE: The vehicle has to be driven in A4WD 30 mph or greater and/or encounter a slip condition before the A4WD lamp will flash for certain faults. NOTE: Complete the entire pinpoint test related to the symptom before replacing the GEM. CONDITIONS A1 CHECK THE IGNITION STATES MONITOR THE PID IGN_GEM DETAILS/RESULTS/ACTIONS NGS Monitor the PID IGN_GEM while turning the ignition switch through the START, RUN, OFF, and ACC positions. Do the PID values agree with the ignition switch positions? A2 RETRIEVE THE DIAGNOSTIC TROUBLE CODES (DTCS) GO to A2. REPAIR the ignition circuit (RUN/ACC: circuit 297 [BK/LG], RUN: circuit 687 [GY/Y], or START: circuit 32 [R/LB]) in question. CLEAR the DTCs. TEST the system for proper operation. Retrieve Continuous DTCs Clear Continuous DTCs Retrieve On- DTCs Are any DTCs recorded? If DTC B1342, REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. If DTC P0500, GO to Pinpoint Test C. If DTC P1483, GO to Pinpoint Test C. If DTC P1485, GO to Pinpoint Test C. If DTC P1804, REFER to Section If DTC P1806, REFER to Section If DTC P1808, REFER to Section If DTC P1810, REFER to Section If DTC P1812, GO to Pinpoint Test B or Pinpoint Test C. If DTC P1815, GO to Pinpoint Test B or Pinpoint Test C. If DTC P1820, GO to Pinpoint Test B. If DTC P1822, GO to Pinpoint Test B. If DTC P1824, GO to A19.

7 Page 7 of 64 If DTC P1826, REPAIR all other DTCs first, then GO to A23. If DTC P1828, GO to Pinpoint Test B. If DTC P1830, GO to Pinpoint Test B. If DTC P1832, GO to Pinpoint Test D. If DTC P1834, GO to Pinpoint Test D. If DTC P1836, GO to A10. If DTC P1837, GO to A10. If DTC P1846, GO to Pinpoint Test B or Pinpoint Test C. If DTC P1850, GO to Pinpoint Test B or Pinpoint Test C. If DTC P1854, GO to Pinpoint Test B or Pinpoint Test C. If DTC P1858, GO to Pinpoint Test B or Pinpoint Test C. If DTC P1868, REFER to Section If DTC P1869, REFER to Section If DTC P1874, GO to A6. If DTC P1876, GO to Pinpoint Test D. If DTC P1877, GO to Pinpoint Test D. If DTC P1886, GO to A27. If DTC P1891, GO to Pinpoint Test B or Pinpoint Test C. If DTC C1107, GO to A3. GO to A3. A3 CHECK THE 4WABS MODULE INPUT; 4WABS MODULE CONNECTED MONITOR THE PID PWR_RLY Monitor the PID PWR_RLY. Does the PID PWR_RLY indicate ON? GO to A4. GO to A6. A4 CHECK THE 4WABS MODULE INPUT; 4WABS MODULE DISCONNECTED MONITOR THE PID PWR_RLY 4WABS Module Monitor the PID PWR_RLY. Does the PID PWR_RLY indicate ON? GO to A5. A5 CHECK CIRCUIT 239 (W/O) FOR SHORT TO POWER REPLACE the 4WABS module; REFER to Section CLEAR the DTCs. TEST the system for normal operation.

8 Page 8 of 64 GEM C240 Measure the voltage between GEM C240-1, circuit 239 (W/O), and ground. Is any voltage indicated? REPAIR circuit 239 (W/O). CLEAR the DTCs. TEST the system for normal operation. A6 CHECK HALL EFFECT POWER CIRCUIT FOR SHORT TO GROUND MONITOR THE PID HALLPWR REPLACE GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. Place the mode switch in the A4WD position. Monitor the PID HALLPWR. Does the PID HALLPWR indicate OFF? GO to A7. GO to A10. A7 CHECK THE HALL EFFECT CIRCUIT FOR SHORT TO GROUND TRANSFER CASE ASSEMBLY C201 DISCONNECTED Disconnect transfer case assembly C201 for Navigator or C111 for Expedition. Cycle the ignition switch OFF then ON.

9 Page 9 of 64 Monitor the PID HALLPWR. Does the PID HALLPWR indicate OFF? GO to A9. A8 CHECK FRONT AND REAR HALL EFFECT SENSORS GO to A8. Measure the resistance between transfer case assembly C201 pin 2, circuit 772 (LB) component side and transfer case assembly C201 pin 6, circuit 682 (DB) component side; and between transfer case assembly C201 pin 4, circuit 435 (Y/LB) component side and transfer case assembly C201 pin 8, circuit 682 (DB) component side. Are the resistances less than 10,000 ohms? If terminals 2 and 6 are less than 10,000 ohms, REPLACE rear Hall effect sensor. CLEAR the DTCs. TEST the system for normal operation. If terminals 4 and 8 are less than 10,000 ohms, REPLACE front Hall effect sensor. CLEAR the DTCs. TEST the system for normal operation. A9 CHECK CIRCUIT 774 (LG) FOR SHORT TO GROUND REPAIR circuit 774 (LG). CLEAR the DTCs. TEST the system for normal operation. GEM C241 Measure the resistance between transfer case assembly C201-3, circuit 774 (LG), and ground; and between transfer case assembly C201-7, circuit 774 (LG), and ground. Are the resistances greater than 10,000 ohms? A10 MONITOR THE FRONT AND REAR HALL EFFECT PIDS TRA_RSP AND TRA_FSP REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. REPAIR circuit 774 (LG). CLEAR the DTCs. TEST the system for normal operation. Place the mode switch in the A4WD position.

10 Page 10 of 64 Monitor the PIDs TRA_RSP, TRA_FSP and VSS_GEM. Drive the vehicle at 48 kph (30 mph) or greater. Are the PIDs TRA_RSP and TRA_FSP within 3 kph (2 mph) of the VSS_GEM? GO to A19. If both PIDs TRA_RSP and TRA_FSP indicate 0 kph, GO to A11. If only one PID indicates 0 kph, GO to A14. A11 CHECK THE VOLTAGE TO THE HALL EFFECT SENSORS CIRCUIT 774 (LG) If both PIDs indicate greater than 0 kph, but are not within 3 kph ( 2 mph) of each other, check for possible Hall effect misalignment, or toothed wheel concern. Transfer Case Assembly C201 Measure the voltage between transfer case assembly C201-3, circuit 774 (LG), and ground; and between transfer case assembly C201-7, circuit 774 (LG), and ground. Are the voltages greater than 10 volts? GO to A13. A12 CHECK CIRCUIT 774 (LG) FOR OPEN GO to A12. GEM C241 Measure the resistance between transfer case assembly C201-3, circuit 774 (LG), and GEM C241-1, circuit 774 (LG); and between transfer case assembly C201-7, circuit 774 (LG), and GEM C241-1, circuit 774 (LG)

11 Page 11 of 64 Are the resistances less than 5 ohms? REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. A13 CHECK CIRCUIT 682 (DB) FOR OPEN REPAIR circuit 774 (LG). CLEAR the DTCs. TEST the system for normal operation. GEM C239 Measure resistance between transfer case assembly C201-6, circuit 682 (DB), and GEM C239-21, circuit 682 (DB); and between transfer case assembly C201-8, circuit 682 (DB), and GEM C239-21, circuit 682 (DB). Are the resistances less than 5 ohms? A14 CHECK THE VOLTAGE TO THE HALL EFFECT SENSORS CIRCUIT 774 (LG) REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. REPAIR circuit 682 (DB). CLEAR the DTCs. TEST the system for normal operation. Transfer Case Assembly C201 If the rear Hall effect sensor is not indicating properly, measure the voltage between transfer case assembly C201-3, circuit 774 (LG), and ground. If the front Hall effect sensor is not indicating properly, measure the voltage between transfer case assembly C201-7, circuit 774 (LG), and ground. Are the voltages greater than 10 volts? GO to A15. A15 CHECK THE HALL EFFECT SENSOR GROUND CIRCUITS 682 (DB) FOR OPEN REPAIR circuit 774 (LG). CLEAR the DTCs. TEST the system for normal operation.

12 Page 12 of 64 GEM C239 If the rear Hall effect sensor is not indicating properly, measure the resistance between transfer case assembly C201-6, circuit 682 (DB), and GEM C239-21, circuit 682 (DB). If the front Hall effect sensor is not indicating properly, measure the resistance between transfer case assembly C201-8, circuit 682 (DB), and GEM C239-21, circuit 682 (DB). Are the resistances less than 5 ohms? GO to A16. A16 CHECK CIRCUIT 435 (Y/LB)/722 (LB) FOR OPEN REPAIR circuit 682 (DB). CLEAR the DTCs. TEST the system for normal operation. GEM C241 If the rear Hall effect sensor is not indicating properly, measure the resistance between transfer case assembly C201-2, circuit 722 (LB), and GEM C241-5, circuit 722 (LB). If front Hall effect sensor is not indicating properly, measure the voltage between transfer case assembly C201-4, circuit 435 (Y/LB) and GEM C241-6, circuit 435 (Y/LB). Are the resistances less than 5 ohms? GO to A17. A17 CHECK CIRCUIT 435 (Y/LB)/772 (LB) FOR SHORT TO GROUND REPAIR circuit 722 (LB)/435 (Y/LB). CLEAR the DTCs. TEST the system for normal operation. If the rear Hall effect sensor is not indicating properly, measure the resistance between transfer case assembly C201-2, circuit 772 (LB), and ground. If the front Hall effect sensor is not indicating properly, measure the resistance between transfer case assembly C201-4, circuit 435 (Y/LB), and ground. Are the resistances greater than 10,000 ohms? GO to A18. A18 CHECK CIRCUIT 435 (Y/LB)/772 (LB) FOR SHORT TO POWER REPAIR circuit 435 (Y/LB)/772 (LB). CLEAR the DTCs. TEST the system for normal operation. If the rear Hall effect sensor is not indicating properly, measure the voltage between transfer case assembly

13 Page 13 of 64 C201-2, circuit 772 (LB), and ground. If the front Hall effect sensor is not indicating properly, measure the voltage between transfer case assembly C201-4, circuit 435 (Y/LB), and ground. Is any voltage indicated? A19 MONITOR THE A4WD CLUTCH RELAY PID 4WDCLST REPAIR circuit 435 (Y/LB)/772 (LB). CLEAR the DTCs. TEST the system for normal operation. REPLACE the inoperative Hall effect sensor(s). CLEAR the DTCs. TEST the system for normal operation. If concern still exists, REPLACE the GEM; REFER to Section TEST the system for normal operation. Monitor the PID 4WDCLST. Place the mode switch in the A4WD position. Does the PID 4WDCLST indicate ON--- when in the A4WD mode? GO to A27. A20 CHECK CIRCUIT 976 (O) FOR SHORT TO POWER If the PID 4WDCLST indicates OFFO-G, GO to A20. GEM C241 Measure the voltage between GEM C241-15, circuit 976 (O), and ground. Is any voltage indicated? REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation.

14 Page 14 of 64 A21 CHECK CIRCUIT 976 (O) FOR SHORT TO GROUND GO to A21. A4WD Clutch Relay C293 Measure the resistance between A4WD clutch relay C293-D, circuit 976 (O), and ground. Is the resistance greater than 10,000 ohms? GO to A22. A22 CHECK CIRCUIT 976 (O) FOR OPEN REPAIR circuit 976 (O). CLEAR the DTCs. TEST the system for normal operation. Measure the resistance between A4WD clutch relay C293-D, circuit 976 (O), and GEM C241-15, circuit 976 (O). Is the resistance less than 5 ohms? A23 MONITOR THE A4WD CLUTCH RELAY PID 4WDCLST REPLACE the A4WD clutch relay. CLEAR the DTCs. TEST the system for normal operation. REPAIR circuit 976 (O). CLEAR the DTCs. TEST the system for normal operation. Monitor the PID 4WDCLST. Rotate the mode switch between 2H and A4WD modes. Does the PID 4WDCLST indicate ON--- when in the A4WD mode and is the A4WD lamp not flashing? GO to A24.

15 Page 15 of 64 A24 MONITOR THE PID 4WDCLST REAR WHEELS BREAKING TRACTION GO to A2 and verify all other DTCs are repaired. Monitor the PID 4WDCLST. Verify the vehicle is in A4WD mode. Position the rear wheels on a loose or slippery surface. Accelerate briefly to get the rear wheels to break traction. Does the A4WD lamp begin to flash and the PID 4WDCLST indicate OFF? GO to A25. A25 MONITOR THE PID 4WDCLST FOR ON--- RESPONSE CHECK transfer case assembly C201 for intermittent short. GEM C241 Place the mode switch in the A4WD position. Monitor the PID 4WDCLST. Does the PID 4WDCLST indicate OFFO-G? GO to A26. A26 CHECK CIRCUIT 976 (O) FOR SHORT TO POWER If the PID 4WDCLST indicates ON---, REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. A4WD Clutch Relay C293 Measure the voltage between A4WD clutch relay C293-D, circuit 976 (O), and ground.

16 Page 16 of 64 Is any voltage indicated? REPAIR circuit 976 (O). CLEAR the DTCs. TEST the system for normal operation. A27 CHECK THE A4WD OUTPUT REPLACE the A4WD clutch relay. CLEAR the DTCs. TEST the system for normal operation. Transfer Case Assembly C201 NOTE: The CLCH SOL active command is located in the Shift Clutch Control active command menu. Set the active command CLCH SOL to ENERGIZED. Measure the voltage between transfer case assembly C201-16, circuit 779 (BR), and ground. Is the voltage less than 5 volts when the active command is set to 0% and greater than 10 volts when set to 100%? REPAIR the transfer case clutch; REFER to Section B. CLEAR the DTCs. TEST the system for normal operation. A28 CHECK CIRCUIT 779 (BR) FOR OPEN GO to A28. A4WD Clutch Relay C293 Measure the resistance between A4WD clutch relay C293-B, circuit 779 (BR), and transfer case assembly C201-16, circuit 779 (BR). Is resistance less than 5 ohms? GO to A29. REPAIR circuit 779 (BR). CLEAR the DTCs. TEST the system for normal operation.

17 Page 17 of 64 A29 CHECK CIRCUIT 779 (BR) FOR SHORT TO GROUND Measure the resistance between transfer case assembly C201-16, circuit 779 (BR), and ground. Is the resistance greater than 10,000 ohms? GO to A30. A30 CHECK CIRCUIT 779 (BR) FOR SHORT TO POWER REPAIR circuit 779 (BR). CLEAR the DTCs. TEST the system for normal operation. Measure the voltage between transfer case assembly C201-16, circuit 779 (BR), and ground. Is any voltage indicated? A31 CHECK A4WD CLUTCH RELAY CIRCUIT 57 (BK) FOR OPEN REPAIR circuit 779 (BR). CLEAR the DTCs. TEST the system for normal operation. GO to A31. Measure the resistance between A4WD clutch relay C293-C, circuit 57 (BK), and ground. Is the resistance less than 5 ohms? GO to A32. A32 CHECK THE VOLTAGE TO THE A4WD CLUTCH RELAY CIRCUIT 704 (DG/LG) REPAIR circuit 57 (BK). CLEAR the DTCs. TEST the system for normal operation. Measure the voltage between A4WD clutch relay C293-A, circuit 704 (DG/LG), and ground.

18 Page 18 of 64 Is the voltage greater than 10 volts? REPLACE the A4WD clutch relay. CLEAR the DTCs. TEST the system for normal operation. REPAIR circuit 704 (DG/LG). CLEAR the DTCs. TEST the system for normal operation. PINPOINT TEST B: THE VEHICLE DOES NOT SHIFT BETWEEN 2WD/A4WD AND 4WD MODES PROPERLY NOTE: Complete the entire pinpoint test related to the symptom before replacing the GEM. CONDITIONS B1 CHECK THE IGNITION STATES MONITOR THE PID IGN_GEM DETAILS/RESULTS/ACTIONS NGS Monitor the PID IGN_GEM while turning the ignition switch through the START, RUN, OFF, and ACC positions. Do the PID values agree with the ignition switch positions? B2 RETRIEVE THE DIAGNOSTIC TROUBLE CODES (DTCS) GO to B2. REPAIR the ignition circuit (RUN/ACC: circuit 297 [BK/LG], RUN: circuit 687 [GY/Y], or START: circuit 32 [R/LB]) in question. CLEAR the DTCs. TEST the system for normal operation. Retrieve Continuous DTCs Clear Continuous DTCs Retrieve On- DTCs Are any DTCs recorded? If DTC B1342, REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. If DTC P0500, GO to Pinpoint Test C. If DTC P1483, GO to Pinpoint Test C. If DTC P1485, GO to Pinpoint Test C. If DTC P1804, REFER to Section If DTC P1806, REFER to Section If DTC P1808, REFER to Section

19 Page 19 of 64 If DTC P1810, REFER to Section If DTC P1812, GO to B6 or Pinpoint Test C. If DTC P1815, GO to B6 or Pinpoint Test C. If DTC P1820, GO to B17. If DTC P1822, GO to B17. If DTC P1824, GO to Pinpoint Test A. If DTC P1826, GO to Pinpoint Test A. If DTC P1828, GO to B17. If DTC P1830, GO to B17. If DTC P1832, GO to Pinpoint Test D. If DTC P1834, GO to Pinpoint Test D. If DTC P1836, GO to Pinpoint Test A. If DTC P1837, GO to Pinpoint Test A. If DTC P1846, GO to B34. If DTC P1850, GO to B34. If DTC P1854, GO to B34. If DTC P1858, GO to B34. If DTC P1868, REFER to Section If DTC P1869, REFER to Section If DTC P1874, GO to Pinpoint Test A. If DTC P1876, GO to Pinpoint Test D. If DTC P1877, GO to Pinpoint Test D. If DTC P1886, GO to Pinpoint Test A. If DTC P1891, GO to B34 or Pinpoint Test C. If DTC C1107, GO to Pinpoint Test A. B3 CHECK THE A4WD INDICATOR GO to B3. NOTE: The A4WD LAMP active command is located in the 4WD Indicators active command menu. Toggle the active command A4WD LAMP on, then off. The A4WD indicator should illuminate, then go off. Does the indicator operate correctly? GO to B4. B4 CHECK THE 4H INDICATOR GO to Section NOTE: The 4WD MODE L active command is located in the 4WD Indicators active command menu. Toggle the active command 4WD MODE L on, and off. The 4x4 indicator should illuminate, then go off. Does the indicator operate correctly? GO to B5. B5 CHECK THE 4L INDICATOR REFER to Section NOTE: The LOW LAMP active command is located in the 4-Wheel Electronic Shift active command menu. Toggle the active command LOW LAMP on and off. The 4x4 LOW indicator should illuminate, then go off. Does the indicator operate correctly? GO to B6. REFER to Section

20 Page 20 of 64 B6 MONITOR THE MODE SWITCH PID 4WDSGEM Monitor the PID 4WDSGEM. Rotate the mode switch through the 2H, A4WD, 4H, and 4L positions. Does the PID 4WDSGEM agree with the A4WD switch positions? GO to B13. B7 CHECK THE MODE SWITCH GO to B7. Mode Switch C230 Rotate the mode switch to the 2H, A4WD, 4H, and 4L positions. Measure the resistance between mode switch terminals 2 and 3 while rotating the mode switch through all switch positions; refer to the following chart. Switch Position Resistance Range 2H ohms A4WD ohms 4H ohms 4L ohms Are the resistances within specification? GO to B8. B8 CHECK CIRCUIT 780 (DB) FOR OPEN REPLACE the mode switch. CLEAR the DTCs. TEST the system for normal operation. GEM C241 Measure the resistance between mode switch C230-3, circuit 780 (DB), and GEM C241-8, circuit 780 (DB).

21 Page 21 of 64 Is the resistance less than 5 ohms? GO to B9. B9 CHECK CIRCUIT 780 (DB) FOR SHORT TO GROUND REPAIR circuit 780 (DB). CLEAR the DTCs. TEST the system for normal operation. Measure the resistance between mode switch C230-3, circuit 780 (DB), and ground. Is the resistance greater than 10,000 ohms? GO to B10. B10 CHECK CIRCUIT 780 (DB) FOR SHORT TO POWER REPAIR circuit 780 (DB). CLEAR the DTCs. TEST the system for normal operation. Measure the voltage between mode switch C230-3, circuit 780 (DB), and ground. Is any voltage indicated? REPAIR circuit 780 (DB). CLEAR the DTCs. TEST the system for normal operation. B11 CHECK CIRCUIT 682 (DB) FOR OPEN GO to B11. GEM C239 Measure the resistance between mode switch C230-2, circuit 682 (DB), and GEM C239-21, circuit 682 (DB).

22 Page 22 of 64 Is the resistance less than 5 ohms? GO to B12. B12 CHECK CIRCUIT 682 (DB) FOR SHORT TO POWER REPLACE circuit 682 (DB). CLEAR the DTCs. TEST the system for normal operation. Measure the voltage between mode switch C230-2, circuit 682 (DB), and ground. Is any voltage indicated? REPAIR circuit 682 (DB). CLEAR the DTCs. TEST the system for normal operation. B13 CHECK THE FRONT AXLE ENGAGEMENT REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. Set the active commands AXLE ENGG to ON and AXLE DSCN to OFF. Drive a short distance. Raise and support the vehicle with the engine running; refer to Section Spin one front tire. The other tire should spin in the opposite direction. Is the axle working properly? EXIT the active command mode and GO to B14. B14 CHECK THE FRONT DRIVESHAFT ENGAGEMENT LOWER the vehicle; GO to Pinpoint Test D. Place the mode switch in the 4H position.

23 Page 23 of 64 Verify the front and rear driveshaft both spin. Is the transfer case locking the front driveshaft to the rear driveshaft? B15 CHECK THE FRONT DRIVESHAFT DISENGAGEMENT GO to B15. If the transfer case is not working properly, GO to B17. Place the mode switch in the 2H position. NOTE: When 4WD is disengaged, the front driveshaft may spin due to viscous drag in the transfer case, especially if cold. If this occurs, the front driveline should be easy to stop. Verify the rear driveshaft is spinning and the front driveshaft is disengaged. Is the rear driveshaft only being driven? GO to B16. B16 CHECK THE FRONT AXLE DISENGAGEMENT If the front driveshaft is not working properly, GO to B17. NOTE: The AXLE ENGG and AXLE DSCN active commands are located in the 4-Wheel Electronic Shift active command menu. Set the active commands AXLE ENGG to OFF and AXLE DSCN to ON. Spin one front tire. The other front tire should not spin. Is the axle disconnect working properly? The 4WD system is OK. B17 MONITOR THE PIDS MTR_CCW and MTR_CW ACTIVE COMMAND CW/CCW ON If the axle disconnect is not working properly, GO to Pinpoint Test D. NOTE: The CW/CCW active command is located in the 4-Wheel Electronic Shift active command menu. Set the active command CW/CCW to ON while monitoring the PIDs MTR_CCW and MTR_CW. Do the PIDs MTR_CCW and MTR_CW indicate ON---? GO to B18. If the PIDs display ON-B-, GO to B23. B18 MONITOR THE PIDS MTR_CCW AND MTR_CW ACTIVE COMMAND CW/CCW TO ON NOTE: The CW/CCW active command is located in the 4-Wheel Electronic Shift active command menu. Set the active command CW/CCW to OFF. Do the PIDs MTR_CCW and MTR_CW indicate OFF---? GO to B26. If the PIDs display OFFO-G, GO to B19.

24 Page 24 of 64 B19 CHECK THE VOLTAGE TO THE TRANSFER CASE SHIFT RELAYS COILS CIRCUIT 704 (DG/LG) Transfer Case Shift Relays C221 Measure the voltage between transfer case shift relays C221-5, circuit 704 (DG/LG), and ground. Is the voltage greater than 10 volts? GO to B20. B20 CHECK CIRCUIT 781 (O/LB) FOR OPEN REPAIR circuit 704 (DG/LG). CLEAR the DTCs. TEST the system for normal operation. GEM C241 Measure the resistance between transfer case shift relays C221-9, circuit 781 (O/LB), and GEM C241-17, circuit 781 (O/LB). Is the resistance less than 5 ohms? GO to B21. B21 CHECK CIRCUIT 782 (BR/W) FOR OPEN REPAIR circuit 781 (O/LB). CLEAR the DTCs. TEST the system for normal operation. Measure the resistance between transfer case shift relays C221-8, circuit 782 (BR/W), and GEM C241-16, circuit 782 (BR/W). Is the resistance less than 5 ohms? GO to B22. B22 CHECK CIRCUITS 781 (O/LB) AND 782 (BR/W) FOR SHORT(S) TO GROUND REPAIR circuit 782 (BR/W). CLEAR the DTCs. TEST the system for normal operation. Measure the resistance between transfer case shift relays C221-8, circuit 782 (BR/W), and ground; and between transfer case shift relays C221-9, circuit 781 (O/LB), and ground.

25 Page 25 of 64 Are the resistances greater than 10,000 ohms? B23 CHECK CIRCUIT 782 (BR/W) FOR SHORT TO POWER GO to B25. REPAIR circuit 781 (O/LB) and/or circuit 782 (BR/W). CLEAR the DTCs. TEST the system for normal operation. Transfer Case Shift Relays Module C221 GEM C241 Measure the voltage between transfer case shift relays C221-8, circuit 782 (BR/W), and ground. Is any voltage indicated? REPAIR circuit 782 (BR/W). CLEAR the DTCs. TEST the system for normal operation. B24 CHECK CIRCUIT 781 (O/LB) FOR SHORT TO POWER GO to B24. Measure the voltage between transfer case shift relays C221-9, circuit 781 (O/LB), and ground. Is any voltage indicated? B25 CHECK THE TRANSFER CASE SHIFT RELAYS COILS REPAIR circuit 781 (O/LB). CLEAR the DTCs. TEST the system for normal operation. GO to B25.

26 Page 26 of 64 Measure the resistance between transfer case shift relays terminal 5 and terminal 8; and between terminal 5 and terminal 9. Are the resistances between 60 and 160 ohms? B26 CHECK THE VOLTAGE TO THE TRANSFER CASE SHIFT MOTOR ACTIVE COMMAND CW/CCW ON REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. REPLACE the transfer case shift relays. CLEAR the DTCs. TEST the system for normal operation. Transfer Case Assembly C201 NOTE: The CW/CCW active command is located in the 4-Wheel Electronic Shift active command menu. Set the active command CW/CCW to ON. Measure the voltage between transfer case assembly C201-14, circuit 778 (O), and ground; and between transfer case assembly C201-15, circuit 777 (Y), and ground. Are the voltages greater than 10 volts? GO to B28. GO to B27. B27 CHECK THE VOLTAGE TO THE TRANSFER CASE SHIFT RELAYS SWITCH SIDE CIRCUIT 704 (DG/LG) Transfer Case Shift Relays C221 Measure the voltage between transfer case shift relays C221-3, circuit 704 (DG/LG), and ground. Is the voltage greater than 10 volts?

27 Page 27 of 64 GO to B31. REPAIR circuit 704 (DG/LG). CLEAR the DTCs. TEST the system for normal operation. B28 CHECK THE VOLTAGE TO THE TRANSFER CASE SHIFT MOTOR ACTIVE COMMAND CW/CCW OFF NOTE: The CW/CCW active command is located in the 4-Wheel Electronic Shift active command menu. Set the active command CW/CCW to OFF. Measure the voltage between transfer case assembly C201-14, circuit 778 (O), and ground; and between transfer case assembly C201-15, circuit 777 (Y), and ground. Are the voltages greater than 10 volts? GO to B29. GO to B30. B29 CHECK CIRCUITS 777 (Y) AND 778 (O) FOR SHORT(S) TO POWER Transfer Case Shift Relays C221 Measure the voltage between transfer case assembly C201-14, circuit 778 (O) and ground; and between transfer case assembly C201-15, circuit 777 (Y), and ground. Is any voltage indicated? REPAIR circuit 778 (O) and/or circuit 777 (Y). CLEAR the DTCs. TEST the system for normal operation. B30 CHECK CIRCUITS 777 (Y) AND 778 (O) FOR OPEN REPLACE the transfer case shift relays. CLEAR the DTCs. TEST the system for normal operation. NOTE: The CW/CCW active command is located in the 4-Wheel Electronic Shift active command menu. Set the active command CW/CCW to OFF. Measure the resistance between transfer case assembly C201-14, circuit 778 (O) and ground; and between transfer case assembly C201-15, circuit 777 (Y), and ground.

28 Page 28 of 64 Are the resistances less than 5 ohms? RECONNECT the transfer case assembly. GO to B34. B31 CHECK CIRCUIT 777 (Y) FOR OPEN GO to B33. Measure the resistance between transfer case shift relays C221-7, circuit 777 (Y), and transfer case assembly C201-15, circuit 777 (Y). Is the resistance less than 5 ohms? GO to B32. B32 CHECK CIRCUIT 778 (O) FOR OPEN REPAIR circuit 777 (Y). CLEAR the DTCs. TEST the system for normal operation. Measure the resistance between transfer case shift relays C221-10, circuit 778 (O), and transfer case assembly C201-14, circuit 778 (O). Is the resistance less than 5 ohms? B33 CHECK THE GROUND TO THE TRANSFER CASE SHIFT RELAYS CIRCUIT 57 (BK) REPLACE the transfer case shift relays. CLEAR the DTCs. TEST the system for normal operation. REPAIR circuit 778 (O). CLEAR the DTCs. TEST the system for normal operation. Transfer Case Shift Relays C221 Measure the resistance between transfer case shift relays C221-1, circuit 57 (BK), and ground.

29 Page 29 of 64 Is the resistance less than 5 ohms? REPLACE the transfer case shift relays. CLEAR the DTCs. TEST the system for normal operation. REPAIR circuit 57 (BK). CLEAR the DTCs. TEST the system for normal operation. B34 CHECK THE CONTACT PLATE SWITCHES MONITOR THE PIDS PLATE_A, PLATE_B, PLATE_C AND PLATE_D Clear the DTCs NOTE: The active command PLATE PWR is located in the 4-Wheel Electronic Shift active command menu. Set the active command PLATE PWR to ON. Monitor the PIDs PLATE_A, PLATE_B, PLATE_C, and PLATE_D. Place the mode switch to the 2H position and record the PIDs. Place the mode switch to the 4H position and record the PIDs. Compare the PIDs with Table 4 Contact Plate Sensor Position Codes in this section. Do the PIDs agree with Table 4? The motor is switching between expected positions. REPAIR the transfer case (7A195) or shift motor assembly; REFER to Section B. CLEAR the DTCs. TEST the system for normal operation. B35 MONITOR THE PID PLATE_A FOR OPEN GO to B35. Transfer Case Assembly C201 NOTE: The active command PLATE PWR is located in the 4-Wheel Electronic Shift active command menu. Set the active command PLATE PWR to ON. Monitor the PID PLATE_A. Does the PID PLATE_A not indicate OPEN?

30 Page 30 of 64 GO to B37. GO to B36. B36 CHECK CIRCUIT 771 (P/Y) TO THE CONTACT PLATE SWITCH A Connect a jumper wire between transfer case assembly C201-10, circuit 762 (Y/W) and C201-5 circuit 771 (P/Y). Monitor the PID PLATE_A. Does the PID PLATE_A indicate CLOSED? GO to B42. B37 CHECK CIRCUIT 771 (P/Y) FOR SHORT TO GROUND GO to B38. GEM C241 Measure the resistance between transfer case assembly C201-5, circuit 771 (P/Y), and ground. Is the resistance greater than 10,000 ohms? REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. B38 CHECK CIRCUIT 771 (P/Y) FOR OPEN REPAIR circuit 771 (P/Y). CLEAR the DTCs. CYCLE the ignition switch to OFF, then ON. TEST the system for normal operation. Measure the resistance between transfer case assembly C201-5, circuit 771 (P/Y), and GEM C241-21, circuit 771 (P/Y). Is the resistance less than 5 ohms? GO to B39.

31 Page 31 of 64 B39 CHECK CIRCUIT 771 (P/Y) FOR SHORT TO POWER REPAIR circuit 771 (P/Y). CLEAR the DTCs. TEST the system for normal operation. GEM C241 Measure the voltage between transfer case assembly C201-5, circuit 771 (P/Y), and ground. Is any voltage indicated? REPAIR circuit 771 (P/Y). CLEAR the DTCs. CYCLE the ignition switch to OFF, then ON. TEST the system for normal operation. B40 CHECK CIRCUIT 762 (Y/W) FOR SHORT TO POWER GO to B40. Transfer Case Assembly C201 Measure the voltage between the GEM C241-12, circuit 762 (Y/W), and ground. Is any voltage indicated? REPAIR circuit 762 (Y/W). CLEAR the DTCs. CYCLE the ignition to OFF, then ON. TEST the system for normal operation. B41 CHECK CIRCUIT 762 (Y/W) FOR OPEN GO to B41. Measure the resistance between transfer case assembly C201-10, circuit 762 (Y/W), and GEM C241-12, circuit 762 (Y/W).

32 Page 32 of 64 Is the resistance less than 5 ohms? REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. B42 MONITOR THE PID PLATE_B FOR OPEN REPAIR circuit 762 (Y/W). CLEAR the DTCs. CYCLE the ignition switch to OFF, then ON. TEST the system for normal operation. NOTE: The active command PLATE PWR is located in the 4-Wheel Electronic Shift active command menu. Set the active command PLATE PWR to ON. Monitor the PID PLATE_B. Does the PID PLATE_B not indicate OPEN? GO to B44. GO to B43. B43 CHECK CIRCUIT 770 (W) TO THE CONTACT PLATE SWITCH B Connect a jumper wire between transfer case assembly C201-10, circuit 762 (Y/W), and C201-1, circuit 770 (W). Monitor the PID PLATE_B. Does the PID PLATE_B indicate CLOSED? GO to B47. B44 CHECK CIRCUIT 770 (W) FOR SHORT TO GROUND GO to B45. GEM C241 Measure the resistance between transfer case assembly C201-1, circuit 770 (W), and ground.

33 Page 33 of 64 Is the resistance greater than 10,000 ohms? REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. B45 CHECK CIRCUIT 770 (W) FOR OPEN REPAIR circuit 770 (W). CLEAR the DTCs. CYCLE the ignition switch to OFF, then ON. TEST the system for normal operation. Measure the resistance between transfer case assembly C201-1, circuit 770 (W), and GEM C241-20, circuit 770 (W). Is the resistance less than 5 ohms? GO to B46. B46 CHECK CIRCUIT 770 (W) FOR SHORT TO POWER REPAIR circuit 770 (W). CLEAR the DTCs. CYCLE the ignition switch to OFF, then ON. TEST the system for normal operation. GEM C241 Measure the voltage between transfer case assembly C201-1, circuit 770 (W), and ground. Is any voltage indicated? REPAIR circuit 770 (W). CLEAR the DTCs. CYCLE the ignition to OFF, then ON. TEST the system for normal operation. B47 MONITOR THE PID PLATE_C FOR OPEN REPLACE the GEM; REFER to Section CLEAR the DTCs. CYCLE the ignition to OFF, then ON. TEST the system for normal operation. NOTE: The active command PLATE PWR is located in the 4-Wheel Electronic Shift active command menu. Set the active command PLATE PWR to ON. Monitor the PID PLATE_C.

34 Page 34 of 64 Does the PID PLATE_C not indicate OPEN? GO to B49. GO to B48. B48 CHECK CIRCUIT 764 (BR/W) TO THE CONTACT PLATE SWITCH C Connect a jumper wire between transfer case assembly C201-10, circuit 762 (Y/W), and C201-9, circuit 764 (BR/W). Monitor the PID PLATE_C. Does the PID PLATE_C indicate CLOSED? B49 CHECK CIRCUIT 764 (BR/W) FOR SHORT TO GROUND GO to B52. GO to B50. GEM C241 Measure the resistance between transfer case assembly C201-9, circuit 764 (BR/W), and ground. Is the resistance greater than 10,000 ohms? REPLACE the GEM; REFER to Section CLEAR the DTCs. TEST the system for normal operation. B50 CHECK CIRCUIT 764 (BR/W) FOR OPEN REPAIR circuit 764 (BR/W). CLEAR the DTCs. CYCLE the ignition switch to OFF, then ON. TEST the system for normal operation. Measure the resistance between transfer case assembly C201-9, circuit 764 (BR/W), and GEM C241-19, circuit 764 (BR/W).