High/low switch blinking and transfer case faults
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4wd Low
Joined: Jan 2024
Posts: 10
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High/low switch blinking and transfer case faults
Slowly bringing a no-crank/no-start 05 LR3 4.4 with 122K miles back into fighting shape.
Problem: One major issue is the transfer case & high-low switch. When I start or drive the vehicle, the lights on the high-low switch continue to blink. The switch obviously presents an error when I press the switch "Transmission Range Change Not Available." I have tried to calibrate the clutch and position sensor using the GAP IID functionality, but get an error.
What I've done:
I sent my GAP IID fault codes (see below) and an email to GAP tech team who suggested the following:
I tested resistance of each wire from TCM to Transfer Case using the attached wiring diagram. All wires seemed to be working perfectly fine based on my resistance tests.
The GAP team suggested that these faults are MOST commonly related to wiring issues, but I think I've ruled wiring out.
Next they suggested to check the High/Low Range Sensor. Is the sensor a common fault point, or is there something else I should be considering?
Problem: One major issue is the transfer case & high-low switch. When I start or drive the vehicle, the lights on the high-low switch continue to blink. The switch obviously presents an error when I press the switch "Transmission Range Change Not Available." I have tried to calibrate the clutch and position sensor using the GAP IID functionality, but get an error.
What I've done:
I sent my GAP IID fault codes (see below) and an email to GAP tech team who suggested the following:
Replacing the TCCM will not fix this. The following needs addressing, wiring attached,
P0806-00 Clutch Position Sensor Circuit Range/Performance - No sub type information
Clutch and range change mechanism calibration failure
Calibrate the clutch and range change mechanism using the manufacturer approved diagnostic system. If fault is still present check the transfer box wiring, especially the transfer box motor wiring, transfer box motor hall effect sensor wiring and transfer box range position sensor wiring. In box of manual transmission variant also check x-sensor, y-sensor and manual transmission output speed sensor wiring
P2789-00 Clutch Adaptive Learning at Limit - No sub type information
Clutch not calibrated
Error occurred during clutch calibration
Check the clutch condition. Calibrate as necessary using the manufacturer approved diagnostic system. If fault is still present check transfer box wiring. Especially check transfer box motor wiring and transfer box motor hall effect sensor wiring
P0806-00 Clutch Position Sensor Circuit Range/Performance - No sub type information
Clutch and range change mechanism calibration failure
Calibrate the clutch and range change mechanism using the manufacturer approved diagnostic system. If fault is still present check the transfer box wiring, especially the transfer box motor wiring, transfer box motor hall effect sensor wiring and transfer box range position sensor wiring. In box of manual transmission variant also check x-sensor, y-sensor and manual transmission output speed sensor wiring
P2789-00 Clutch Adaptive Learning at Limit - No sub type information
Clutch not calibrated
Error occurred during clutch calibration
Check the clutch condition. Calibrate as necessary using the manufacturer approved diagnostic system. If fault is still present check transfer box wiring. Especially check transfer box motor wiring and transfer box motor hall effect sensor wiring
The GAP team suggested that these faults are MOST commonly related to wiring issues, but I think I've ruled wiring out.
Next they suggested to check the High/Low Range Sensor. Is the sensor a common fault point, or is there something else I should be considering?
Last edited by traen10; Jan 21, 2025 at 03:02 PM.
Camel Trophy
Joined: Nov 2017
Posts: 4,995
Likes: 962
From: Green Bay, WI
If you tested the wires, can I assume the three items on the case have been unplugged, plugged back in? Oddly that is a common fix at time for slight corrosion issues on contacts.
What we need is codes though, you have not mentioned any that you are getting - its not clear if the one GAP mentions is one or the only one?
What we need is codes though, you have not mentioned any that you are getting - its not clear if the one GAP mentions is one or the only one?
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4wd Low
Joined: Jan 2024
Posts: 10
Likes: 0
I'm pretty sure I would have unplugged/plugged back in all three connectors given I tested resistance of each transfer case lead back to the corresponding pin back on TCM connector pin. I cleaned them as well with basic electronic cleaner and also DeoxIT D100L-25C, especially on the TCM side where there had been corrosion previously. It might be worthy trying again on the transfer case connectors side though.
For fault codes, they were embedded in my original message, but to be clear here they are:
P0806-00 Clutch Position Sensor Circuit Range/Performance - No sub type information
Clutch and range change mechanism calibration failure
Calibrate the clutch and range change mechanism using the manufacturer approved diagnostic system.
P2789-00 Clutch Adaptive Learning at Limit - No sub type information
Clutch not calibrated
Error occurred during clutch calibration
Check the clutch condition. Calibrate as necessary using the manufacturer approved diagnostic system.
For fault codes, they were embedded in my original message, but to be clear here they are:
P0806-00 Clutch Position Sensor Circuit Range/Performance - No sub type information
Clutch and range change mechanism calibration failure
Calibrate the clutch and range change mechanism using the manufacturer approved diagnostic system.
P2789-00 Clutch Adaptive Learning at Limit - No sub type information
Clutch not calibrated
Error occurred during clutch calibration
Check the clutch condition. Calibrate as necessary using the manufacturer approved diagnostic system.
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