Transfer case actuator module

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2002 Sport Trac, 315,00 miles and still rollin’
Sep 5, 2022
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Cleveland, Ohio
Hello all, I have a 2002 Sport Trac with 315k miles. The 4x4 does not engage unless it is summertime, or, if it’s winter (I live in Cleveland, OH), I must first allow the engine to totally warm up if I want the 4x4 to engage immediately with a turn of the switch. What I believe is that the 4WD actuator motor in the transfer case is getting flakey/weak. What I am looking for is the location of the actuator motor, any videos showing actuator motor removal, and any insight to swapping this out from my friends here on this forum.

Thanks, and enjoy the day.


Well-Known Member
V6 Engine
4 wheel drive
2001 job 2
Mar 7, 2020
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Got here a 2001 SportTracJob2, near identical twin to your 2002.
Sounds like your 4x4ShiftMotor has gotten weak due to age & rare use; needs replacement.
Beware: seems to be a lot of chaos in FordMotorCraft+AfterMarket part numbers for these components.
Jack\Ramp vehicle high enough, EBrake+WheelBlocks, crawl under drivers door, 4 Bolts + 1 HarnessPlug.
While there likely need to renew TransferCase MerconLV, not Mercon\MerconV; needed every 4yr\33kMile.
Can remove CounterWeight while doing this work, just to get it out of the way.
Click here for my wiki page on this 1354 TransferCase+Controls.

4x4TransferCase controls basicly consist of 3 parts:

~ 4x4ShiftMotor, mounted directly under DriverSeat, rear side of TransferCase, pic below.
A NotoriousFailureItem, barely large enough to do its job, especially if not exercised routinely.
2Wire12vMotor With 5Wire3PosLimitSwitch+7WireCable+8PinRoundSocket WOut ClutchRelayBrownWire
FactoryLabel\Stamp BorgWarner# 1354-648-009-c \ 07-31-00 \ 10167226 \ mo25m \ 590912 \ 0195
~ 4x4ControlMode, mounted behind LeftPassenger KickPanel, pic below.
Also a NotoriousFailureItem, CircuitBoard components\relays undersized & often burn out.
FactoryLabel\Stamp Motorola# 01MP20701 \ m799g \ 00240 \ 20628416
~ 4x4DashSelectorSwitch+Knob, 2WHi~4WHi~4WLo, mounted in DashCenterPanel, pic below.
There's also a "hidden" NeutralPosition for RVFlatTowing, requires a special DealerInstalledMod.
This rarely fails, leave it alone.
2001.Ford_TrCs.Case_Borg.1354_000b.GIF 2001.Ford_TrCs.Case_Borg.1354_000c.GIF 2001.Ford_TrCs.Mdul_Ford.1L54-7h417-ab,ac,ad,ae.GIF 2001.Ford_TrCs.Swch_Ford.f87z-9c68-ba+f57z-11666-a.GIF
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