Gen 3 Montero, won't engage 4Llc but 4H and 4Hlc work

[122andy]

One thing I did notice...the diff lock won't disengage when shifting from 4Hlc to 4H. I've tried rolling backward in neutral, putting it in reverse and going backward etc. The only way I can get the diff to unlock is by shifting to 2h. Is this how it's supposed to work?

 

[Inyo_man]

The o my way I can get the diff to unlock is by shifting to 2h. Is this how it's supposed to work?

You should be able to unlock the center diff. lock when shifting from 4Hlc to 4H without putting it in 2H.

 

[122andy]

Thanks. Just helps me figure out what isnt working properly so I can keep trying to trouble shoot it.

I think Im just gonna have to take a break and say to hell with it for awhile and just drive it. At this point I am burnt out and done with it. Im going to have to take the console apart and start testing the 4wd shifter, the Transfer ECU and get really deep into troubleshooting. That and not being able to reset the ABS codes its throwing...either I take it to Satan(the dealer) and have em erase codes or drop $600 on a MUT.

 

[Inyo_man]

It sounds like you've gone through your system really well, but perhaps this might help with your troubleshooting.

Cheers.

http://www.4x4wire.com/forums/ubbth...Y_-_Pajero_Flashing_4x4_dash.html#Post1101829

 

[122andy]

It sounds like you've gone through your system really well, but perhaps this might help with your troubleshooting.

Cheers.

http://www.4x4wire.com/forums/ubbth...Y_-_Pajero_Flashing_4x4_dash.html#Post1101829

I appreciate it, I used that page as a reference already. He has a cool write-up on a TCC lockup as well. I wish I knew which switch he was referring to by "#5 switch". When I ohm'd mine none of the switches behaved that way and none of the new switches did either. Also he mentioned one of the switches being a ball switch, none of my old or new ones were either. I do know that at least one of the switches on the gen2 or 2.5 was a ball style though

 

[MoabRefugee]

Check your 4wd Selector

When I purchased my 01 last year it had the 4wd disco dash. Much like you have, I replaced the vac solenoid for the front, and went through all sensors, etc. I remembered the dealer's mechanic had mentioned "working the transfer case lever real good". IN addition to his poor grammar, I think he believed it was a mechanical selector. This was the same mechanic that rebuilt the door ajar switches that were "causing a dead battery"...I adjusted the strike plates after signing the paperwork. Good door seal, and imagine that, the dome lights turned off. Muppet.

I removed and disassembled the selector assembly, and low and behold, the housing was cracked and the plastic tab which moves the switch plate portion was broken off. After debating installing external switches, used assembly, I decided to give repair a go. I bent a heavier gauge brass safety pin into tight radius U with parallel sides. I then heated it an plunged it into the selector shaft. After confirming fit and that it moved the switch plate, I greased and re-assembled. FULLY FUNCTIONAL 4WD.

The lever requires that one depresses it...my theory is that the muppet mechanic gleefully worked the lever back and forth sheering the small plastic tab. Result, lever moved back and forth, but the switch plate remained stationary, causing all manner of ECU control confusion. I wonder how many of these trucks have had this switch sheered off by the ham fisted? I think it is worth a look, and it saved me a ton of money. YMMV. 10k miles and nearly daily use of 4LLC and no problems

 

[122andy]

Thanks, I will def be checking that and will post the results!