Vehicle won't start, it has clutch interlock, which is only activated in 2wd and 4H , vehicle starts in 4L only, clutch switch??

Hook up a scan tool an check for DTC'S - diagnostic trouble codes in the 4X4 control module , or any other module . A simple code reader won't work nor will auto zone auto part store or any other parts store etc... The 4X4 switch is an input to the control module .What transfer case does it have , how many buttons on the 4x4 switch ,is it electronic shift on the fly ?

SECTION 308-07A: Transfer Case - General Information 2004 F-150 Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 06/20/2001 Transfer Case - Electronic Shift on the Fly (ESOF) Operation The electronic shift on the fly (ESOF) system is an electronic shift 4x4 system that allows the operator to choose between two different 4x4 modes as well as 2-wheel drive. The operator can switch between 2WD and 4H mode at speeds up to 88 km/h (55 mph). To engage or disengage 4L range, the vehicle speed must be less than 5 km/h (3 mph), the brake pedal depressed, and the transmission must be in NEUTRAL.
The transfer case is equipped with an electromagnetic clutch which is located inside the case. This clutch is used to spin up the front driveline when shifting from 2WD to 4H mode at speed. When the control switch on the instrument panel is turned, the generic electronic module (GEM) recognizes that a shift has been requested and activates the electromagnetic clutch and the relays which power the transfer case shift motor. When the shift motor reaches the desired position, as determined by the contact plate position inputs to the GEM, power to the shift relays and motors will be removed. When the transfer case front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the mainshaft hub to the drive sprocket. Finally, the front axle collar is engaged and the electromagnetic clutch is deactivated.
Shifts between 2WD and 4H can be made at any speed up to 88 km/h (55 mph). Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes.
Feature Inputs:

• 4WD mode switch (various resistances; go to Table 1).
• Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open; go to Table 4).

Feature Outputs:

• 4x4 shift motor relay outputs (go to Table 2).
• Transfer case clutch relay (grounded when relay is activated, open circuit when relay is deactivated).
• 4x2/4x4 vacuum solenoid (grounded when activated, open circuit when deactivated).
• Cluster indicators (ground when activated, open circuit when deactivated).

When shifting into or out of 4L, the GEM requires that the vehicle speed be less than 5 km/h (3 mph), the brake is applied, and the transmission is in NEUTRAL.
Feature Inputs:

• 4WD Mode Switch (various resistances; go to Table 1).
• Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open; go to Table 4).
• Output Speed Shaft (OSS) Sensor (Sinusoid Signal: 0.7V-20V, 2.2 Hz/mph).
• Brake Input (battery voltage when brake is depressed, open circuit when not activated).
• Transmission Range Sensor (grounded when transmission is in NEUTRAL, open circuit otherwise).
• Start/Clutch Depressed Input (go to Table 3).

Feature Outputs:

• 4x4 Shift Motor Relay Outputs (go to Table 2).
• 4x2/4x4 Vacuum Solenoid (grounded when activated, open circuit when deactivated).
• Cluster Indicators (grounded when activated, open circuit when deactivated).

Does yours have Electronic Shift on the Fly (ESOF) Operation The electronic shift on the fly (ESOF) system is an electronic shift 4x4 system that allows the operator to choose between two different 4x4 modes as well as 2-wheel drive. The operator can switch between 2WD and 4H mode at speeds up to 88 km/h (55 mph). To engage or disengage 4L range, the vehicle speed must be less than 5 km/h (3 mph), the brake pedal depressed, and the transmission must be in NEUTRAL. The transfer case is equipped with an electromagnetic clutch which is located inside the case. This clutch is used to spin up the front driveline when shifting from 2WD to 4H mode at speed. When the control switch on the instrument panel is turned, the generic electronic module (GEM) recognizes that a shift has been requested and activates the electromagnetic clutch and the relays which power the transfer case shift motor. When the shift motor reaches the desired position, as determined by the contact plate position inputs to the GEM, power to the shift relays and motors will be removed. When the transfer case front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the mainshaft hub to the drive sprocket. Finally, the front axle collar is engaged and the electromagnetic clutch is deactivated.

After reading this material I would not think it was the switch . Maybe an input problem to the GEM module .

Feature Inputs:

• 4WD Mode Switch (various resistances; go to Table 1).
• Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open; go to Table 4).
• Output Speed Shaft (OSS) Sensor (Sinusoid Signal: 0.7V-20V, 2.2 Hz/mph).
• Brake Input (battery voltage when brake is depressed, open circuit when not activated).
• Transmission Range Sensor (grounded when transmission is in NEUTRAL, open circuit otherwise).
• Start/Clutch Depressed Input (go to Table 3).
• I would take it and have it check for codes !

02 , just sold mine, best car ever. had, of many.

how do you know that.?

and what are the tires, touching, (dirt, snow,ice, grass , pavement)

what?

this car has part time 4wd, it is not AWD

its not a Grand cheerokee with AWD.

engaging 4wd on ice free pavement is wrong.

http://www.rubicon-trail.com/4WD101/driveline-bind.html



and my fsm states.

read the operators guide in the glove box, it will say....

"2WD is intended to be driven on normal street and highway conditions, such as HARD surfaced roads."

Then

"4H & 4L positions are intended for loose slippery road surfaces only and not intended for normal driving" (They assume paved streets are normal.)

"Driving in 4H or 4L positions on hard surfaces roads, will cause, increased tire wear, and damage to the drive line components."

Unqual tire sizes, will do the same damage. "circumference mismatched"

Last: "do not attmpet to make a shift, while only the front or rear wheels are spinning" No transfer case synchronizer exists and damage will result." (kill the gear dogs, you will)

try the front axle shift activator

If it won't crank, check clutch safety switch and cables for the starter.
If it cranks but won't start, you'll need to find out if it is ignition or fuel to know where to look next.

Transfer Case - Mechanical Shift On The Fly (MSOF) Operation The mechanical shift on the fly (MSOF) system is a manual shift 4WD system that allows the operator to chose between two different 4x4 modes as well as 2-wheel drive. The operator can switch between 2WD and 4H mode at speeds up to 88 km/h (55 mph). To engage or disengage 4L range, the vehicle speed must be less than 5 km/h (3 mph), the brake pedal depressed, and the transmission must be in NEUTRAL.
Shifts between 2H and 4H can be made at a stop or any forward speed up to 88 km/h (55 mph). At temperatures below 0°C (32°F) shifts should not be performed above 72 km/h (45 mph).
The transfer case is equipped with an electromagnetic cluch which is located inside the case. This clutch is used to spin up the front driveline when shifting from 2WD to 4x4 mode at speed. When the manual shift lever is moved, this activates the 4WD indicator switch, 4WD electric clutch relay, and the electromagnetic clutch. When the transfer case front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the mainshaft hub to the drive sprocket. Finally, the front axle collar is engaged and the electromagnetic clutch is deactivated.

Hi - Here is instruction how to do.

From N to 4H

Stop the vehicle completely, place the

transmission in "N" (Neutral) and depress

the brake pedal and the clutch pedal fully

(if equipped), then push in and turn the

switch to shift into "4H".

From 4H to 4H LOCK

You can operate the transfer switch either

when the vehicle is stopped or while the

vehicle is moving.

Position the front wheels straight ahead

and turn the switch to shift into "4H LOCK".

If the vehicle is moving, we recommend

that the speed be less than 100 km/h (60

mph) during this operation.

NOTE:

• When shifting between the transfer

switch position and the transfer gear

position is unmatched, all 4WD indicators

will blink and the buzzer will sound.

• If it is difficult to shift between "4H" and

"4H LOCK" while the vehicle is moving,

try accelerating and decelerating your

vehicle several times after turning the

transfer switch. Be sure to wait until traffic

conditions allow you to accelerate and

decelerate safety before using this procedure.

From 4H LOCK to 4L LOCK

Stop the vehicle completely, place the

transmission in "N" (Neutral) and depress

the brake pedal and the clutch pedal fully

(if equipped), then push in and turn the

switch to shift into "4L LOCK".

From 4L LOCK to 4H LOCK

Stop the vehicle completely, place the

transmission in "N" (Neutral) and depress

the brake pedal and the clutch pedal fully

(if equipped), then push in and turn the

switch to shift into "4H LOCK".

From 4H LOCK to 4H

You can operate the transfer switch either

when the vehicle is stopped or while the

vehicle is moving.

Position the front wheels straight ahead

and turn the switch to shift into "4H". If the

vehicle is moving, we recommend that the

speed be less than 100 km/h (60 mph) during

this operation.

NOTE:

• When shifting between the transfer

switch position and the transfer gear

position is unmatched, all 4WD indicators

will blink and the buzzer will sound.

• If it is difficult to shift between "4H" and

"4H LOCK" while the vehicle is moving,

try accelerating and decelerating your

vehicle several times after turning the

transfer switch. Be sure to wait until traffic

conditions allow you to accelerate and

decelerate safety before using this procedure.

From 4H to N

64J209

Stop the vehicle completely, place the

transmission in "N" (Neutral) and depress

the brake pedal and the clutch pedal fully

(if equipped), then push in and turn the

switch to the mark (1) at the left of the "N"
position, and hold the switch in this posi-

tion for 5 seconds until the "N" indicator

blinks, then turn the switch to the "N" position.

When you turn the transfer switch to the

"N" position, "N" indicator will come on with

the buzzer sound.

CAUTION

• Be sure to stop the vehicle completely

before operating the transfer

switch to shift between "N" and

"4H", or between "4H LOCK" and

"4L LOCK".

• Do not shift between "4H" and "4H

LOCK" unless the front wheels are

in the straight-ahead position and

we recommend that the vehicle

speed be less than 100 km/h (60

mph).

Do not operate the transfer switch

while tires are racing.

• Do not operate your vehicle in "4H

LOCK" or "4L LOCK" on dry, hard

surfaces.

(Continued)

CAUTION

(Continued)

• Do not operate the vehicle while a

4WD mode indicator is blinking

except when shifting between "4H"

and "4L LOCK".

If you operate the vehicle while a

4WD mode indicator is blinking, a

buzzer will sound and the transfer

will shift to "N" (Neutral) to prevent

transfer case damage.

In this case, use the following procedure.

1) Depress the clutch pedal fully (if

equipped) or shift the automatic

transmission gearshift lever to the

"N" position.

2) Turn the transfer switch to the

position previously selected.
3) Operate the transfer switch again.

It should have a safety interlock switch on the clutch to prevent it from cranking with the clutch not depressed. Do a search on the Internet for 94 jeep clutch pedal safety switch. If its an automatic it should have a switch on the transmission linkage to prevent starts out of park.

4 wheel drive is vacuum activated. Check vac motor 1st as it is probably the reason for it not engaging. I had a 88 cherokee w/ bad vac motor which caused exact problem you describe.

Clutch pedals have a safety interlock switch that keeps a manual transmission vehicle from starting. It sounds like the pin on the bottom of the shifter in the trans is getting worn and needs to be replaced. You can remove the boot on the shifter and the cover on top of the trans and see the pin. It's a simple matter of getting the pin out and installing a new one. Just make sure everything lines up good on the install and everything is clean. Another thing that may be the culprit are the synchronizer plates could be worn nearlt out. To replace or fix this you will need the trans out of the vehicle and tear it down. Start with an inspection of the pin and the linkage as well, then if it doesn't work correctly then you may have to tear into it.