How to Replace a Transfer Case Shift Motor On A 4WD/4×4 Ford F-150 or Bronco

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One of our customer’s kindly took notes and created a great set of do-it-yourself instructions for a transfer case encoder/ shift motor on a ford bronco. These were specifically for a 1991 Ford Bronco full size, however they will also work on the following vehicles:

1991-1997 Ford Bronco

1991-1997 Ford  F150

Part Needed: Dorman 600-801

Tools needed:

  • 3/8 Drive Socket & 10MM Socket
  • Drop-light
  • Rubber Mallet
  • Pocket Flathead Screwdriver

There are 4 bolts holding this unit on. One bolt holds the back brace on and 3 hold the housing on. There is one electrical connector.

Step 1. disconnect plug and swing it out of your way. To disconnect connector from unit depress tab on back and slide downward, small flat head screwdriver may help.

Step 2 remove one 10mm bolt from back brace.

Step 3 remove 3 bolts from motor housing to transfer case.

Step 4 unit can be pretty hard to get off( depending on how long it has been on) so you may need to tap it with a rubber mallet.

Installation

Step 1 match the unit female to the transfer case male and slide on.

Step 2.  Line up your bolt holes and start bolts.(you may want to put some thread lock on them to ensure the do not back out)

Step 3.  Tighten all 4 bolts to about 40-50 inch pounds.

Step 4. Connect the connector back and slide onto the new unit.

Now you should be ready to try it out. Double check your work and follow your instructions for 4×4 engagement.

On my bronco there was 3 extra wires that went from the wire harness to the back of the transmission. If you have extra wires, they can be removed from the back of the old wiring harness and then re-installed into the new wiring harness for the new motor. This can be done simply by popping the old weatherpack connector open with a small screwdriver, then slide the extra wires out. The new motor, you can also open the weatherpack connector and slide the new pins into the empty slots. APDTY.com does not recommend cutting any wires.

APDTY.com

Joel

ASE Certified Auto Technician 16+ Years Of Auto Repair Experience

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3 Responses

  1. Robert says:

    Very cool article. I wasn’t aware that this was something I could do myself so easily. Great step by step instructions. I will try to do this next week. Thanks for the great info!

  2. Joe says:

    Great article. I hope that I will be able to try this sometime soon. Very informative website!

  3. smith chris says:

    very helpful glad i could find this! thank you -Chris

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