SENSOR-POSITION
DESCRIPTION
The transfer case position sensor (2) 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
| 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 |
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.
| SENSOR POSITION |
OPERATING MODE |
SENSOR RESISTANCE (ohms) |
| 1 |
2WD |
1124-1243 |
| 2 |
4WD PART TIME |
650-719 |
| 3 |
4WD FULL TIME |
389-431 |
| 4 |
NEUTRAL |
199-221 |
| 5 |
4WD LOW |
57-64 |
REMOVAL
1. Raise and support the vehicle.
2. Disengage the transfer case position sensor connector from the position sensor (2).
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 27 N·m (20 ft.lbs.).
3. Engage the transfer case position sensor connector to the position sensor.
4. Lower vehicle.
5. Verify proper sensor operation.