2002 Ford F250 4wd 7.3 Power Stroke, auto locking hubs “all stock” 186,000 miles.
Tested and changed a bad PVH Solenoid. New one tested good (connector unplugged, 12v to center solenoid lead, jumper wire from left or right lead to ground makes solenoid click and vac. tube to hubs gets vac.)
but when I plug in the three wire connector (key on run, 4wd on, 12v to center lead) the solenoid does not click on to allow vacuum to hubs.

Getting ready to make a trip. Please help..

 

Here is some basic information:

The electronic-shift, 4-wheel drive system consists of the following components:

Transfer case (For transfer case repair procedures, refer to Section 308-07B).
Four-wheel drive (4WD) control module (For 4WD control module installation, refer to 4WD control module in this section.)
Mode select switch (MSS)
Gearmotor encoder assembly
Automatic locking hubs (hub locks)
Pulse vacuum hub lock (PVH) solenoid and vacuum lines

Some other technical references hope its helpful.

four-wheel-drive-4wd-control-module-removal-and-installation.pdf

hublock-vacuum-system-leak-test-general-procedures.pdf

hublock-vacuum-reservoir-removal-and-installation.pdf

gearmotor-encoder-assembly-removal-and-installation.pdf

 

Thanks for the info. Do you know how to test the 4wd control module?
The transfer shifts into 4wd and the 4x4 dash lite comes on but the PVH solenoid does not click on to allow vacuum to hubs. I posted earlier that it is new and tests good without the 3 wire connector plugged into the solenoid.

 

I will see if I can find the connector pin out for the controller maybe we can use that to find the wire that should be working the PVH.

 

Check the easy stuff first like fuses and relays here is the breakdown of the controller wiring.

2002 Ford 4wd 1.pdf

 

The black wire coming off the mode select switch (MSS) is ground for sure and grounds to a group off wires G201.
2002 Ford 4wd grounds .pdf

Here is the instrument cluster which I think houses the MSS. It shows very little and I am not finding a sheet with just the MSS wiring. but we found groud lets see if we can find the power wire.
2002 Ford instrument cluster.pdf

Also check your ABS fuses as a quick check.the ABS is tied into that 4wd control module since the transfer case is shifting into 4wd probably not a speed sensor fault.

Power circuits
2002 Ford 4wd power .pdf
2002 Ford 4wd power 1.pdf