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

[122andy]

I picked up a 02 Limited with 130k miles a few months back. I was aware of the 4wd issues on these when I was looking for one and purchased it anyway with a blinking CD light when engaging 4Hlc and 4Llc. So this is where I'm at with trying to make the 4wd fully operational:
4H works, no issues at all. On gravel all four wheels spin, does not bind up when turning.
4 Hlc works, but CD light flashes when engaged. On gravel all four wheels spin and it binds up when turning.
4 Llc does not work. Acts same as 4Hlc. CD light flashes.

With KOEO, you can hear the actuator move from 2H to 4H. You can again hear it move from 4H to 4Hlc, although a shorter distance. When shifting from 4Hlc to 4Llc it makes no sound. Should it make a sound from 4Hlc to 4Llc? It would be great if someone could check on theirs and let me know.

The first thing I tried was removing all the switches, cleaning both the connector and switch end with electric contact cleaner, checked for resistance while opening and closing the switch. All checked well. But no change in 4wd operation. So I figured what the heck, prob time to replace replace *all* 5 switches as theyre prob bound to start failing soon anyway. Still no change in operation.

I have tirelessly "worked" this thing every which way. Neutral, switch to 4Llc, then letting it roll backwards, forwards, sideways, upside down, engaging, disengaging, putting it in gear, out of gear, on and on. It hasn't "loosened" anything up.

Sometimes it will throw a code when I check them(transfer case codes, 32 I believe) and sometimes it won't. I'm referring to counting CD flashes with diagnostic pin grounded. Regardless 4llc never works whether it is or isn't throwing a code. Just verified it right now, no codes.

I'm wondering if 4Llc operation is tied into the ABS system? When I first got the Montero, I had a code for front left abs sensor. It had a bunch of metal shavings around it when I removed it. I put a new sensor on, still threw same code. Unplugged battery for 20 mins, same code. When I was in the dash not much longer after this, I unplugged the ABS computer and plugged it back in in an attempt to reset it. Ever since then it has thrown an 11, 12, 13, 14, 32, 42, and 52. The ABS light never comes on and the ABS works. I can't shake those codes though. Maybe a MUT would clear them? As a side point, the codes list here http://www.pocuk.com/forums/viewtopic.php?t=153219&sid=8bf6f26496e395e7367bbcf279fe0257 skips over 32. Maybe a typo?

Sorry to be long winded, just trying to cover it all. It

 

[haolepinoy]

Here's a FSM page with code 32

I haven't checked the reference page listed on the right, but would assume it's a diagnostic page. Hope that gives you more to go on.

 

[122andy]

Yeah I actually have that printed out. Looking back in my notes it was actually code 33 not 32. It has only actually given me that code maybe twice out of the 20 times I've checked it.

 

[122andy]

So one of the main things I would like to know is if I should hear the actuator move when shifting from 4hlc to 4llc. If someone could verify for me I would greatly appreciate it!

 

[Michael Brown]

The system in the Limited models is vacuum actuated for the front free wheel clutch. The transfer case is electronic, but both would need the engine running to properly engage between the modes.

Start looking under the vehicle for either a leaking vacuum line on the front axle actuator or a bad connection on the transfer case wires. A broken plug or bad solenoid on the transfer can cause the symptoms you are describing with the center light. Also check the oil level of the transfer case to ensure it has enough fluid to move properly.

It also may just need exercise. When 4WD is not used regularly on a vehicle, the components can get stuck in the default 2WD position. Taking it out somewhere and working the 4WD in several modes can free them and return the system to normal functionality.

Also check here
https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=3&ved=0ahUKEwjc6r6MyITOAhWHHR4KHY3WBY0QFggnMAI&url=http%3A%2F%2F4wd.blogeasy.com%2F&usg=AFQjCNFqkUwjbwfaR6eBZQ8LKvtZ4hIhZw&sig2=oOWbNEcMKvc-RZ7_Rfc56w

 

[122andy]

Thanks for the reply. I did have 7 months of reading and Googling the 4wd system before actually making a purchase. So what Im trying to say is the basics have been covered, now Im moving on from there.

The system in the Limited models is vacuum actuated for the front free wheel clutch. The transfer case is electronic, but both would need the engine running to properly engage between the modes.

I fully understand how the front free wheel clutch works. Its a healthy working system on my Montero. On your Montero, when you have KOEO, what do you hear between 2H an 4H, 4H and 4Hlc, 4Hlc and 4Llc? I only hear the t-case actuator motor move on the first two shifts.

Start looking under the vehicle for either a leaking vacuum line on the front axle actuator or a bad connection on the transfer case wires. A broken plug or bad solenoid on the transfer can cause the symptoms you are describing with the center light. Also check the oil level of the transfer case to ensure it has enough fluid to move properly.

I never brought up the freewheel clutch system, that is not the issue. I have vacuum tested the lines, the freewheel actuator rod extends, I even put new solenoids(by the airbox) in even though the originals ohm'd fine. I also stated that I replaced all 5 switches on the transfer case.

It also may just need exercise. When 4WD is not used regularly on a vehicle, the components can get stuck in the default 2WD position. Taking it out somewhere and working the 4WD in several modes can free them and return the system to normal functionality.

Quoted from my original post: I have tirelessly "worked" this thing every which way. Neutral, switch to 4Llc, then letting it roll backwards, forwards, sideways, upside down, engaging, disengaging, putting it in gear, out of gear, on and on. It hasn't "loosened" anything up. This is being done on gravel mind you.

Also check here
https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=3&ved=0ahUKEwjc6r6MyITOAhWHHR4KHY3WBY0QFggnMAI&url=http%3A%2F%2F4wd.blogeasy.com%2F&usg=AFQjCNFqkUwjbwfaR6eBZQ8LKvtZ4hIhZw&sig2=oOWbNEcMKvc-RZ7_Rfc56w[/QUOTE]Thanks, I had printed that out a few months back, it is what I based my troubleshooting on.

 

[DSouth]

I'd suggest having a go at it with a MUTII code reader if you haven't already. My understanding is that ABS, Traction Control and some(maybe all) Transmission codes are only accessible/clearable via MUTII, but I could be mistaken. Either way probably only ~$100 to find out from a specialist shop.

 

[122andy]

I'd suggest having a go at it with a MUTII code reader if you haven't already. My understanding is that ABS, Traction Control and some(maybe all) Transmission codes are only accessible/clearable via MUTII, but I could be mistaken. Either way probably only ~$100 to find out from a specialist shop.

Actually, ABS, auto trans and transfer case codes can be read by grounding #1 pin on diagnostics port and counting the blinks of the respective systems lights on the dash. Look above at what haolepinoy posted above for example.
I do think a MUT might be needed to actually clear the ABS codes I have, as unplugging the battery or abs control unit don't seem to be working. That or the abs unit is toast. Weird thing is that it doesn't come on driving down the road and the ABS works fine.

 

[122andy]

Could I get someone with a 01-05 or whatever to verify if you hear the t-actuator move when shifting from 4hlc to 4 Llc with KOEO. Thanks!

 

[Inyo_man]

Could I get someone with a 01-05 or whatever to verify if you hear the t-actuator move when shifting from 4hlc to 4 Llc with KOEO. Thanks!

You should be able to hear the actuator when shifting into 4 low.

 

[122andy]

Any guesses on why the CD light flashes in 4Hlc even tho the diff locks? I'm assuming that whatever the reason it that it behaves that way is also the reason it won't go into 4Llc

 

[Inyo_man]

Any guesses on why the CD light flashes in 4Hlc even tho the diff locks? I'm assuming that whatever the reason it that it behaves that way is also the reason it won't go into 4Llc

The only time I've ever had a blinking CD light is when my transfer case fluid needed to be exchanged for Amsoil after I first purchased the rig in 2002.
It has worked flawlessly ever since.

Good Luck.

Click on Transfer Case...
http://www.amsoil.com/lookup/auto-and-light-truck/2002/mitsubishi/montero/5229/us-volume/

 

[Michael Brown]

You can open the fill plug on the side of the transfer case to check the fluid level. I believe it should be even with the bottom of the opening, but I will double check the FSM. There is a drain plug lower for changing oil. The oil I pulled out of mine had some black coloration. New OEM oil is amber.

I've always run OEM LSD gear oil in my Monteros. 20k miles since diff swap and fluids.

https://www.rallysportdirect.com/part/lsd-oil-and-additives/mit-mz320345-mitsubishi-diaqueen-gl5-lsd-gear-oil-1-qt

 

[Inyo_man]

You can open the fill plug on the side of the transfer case to check the fluid level. I believe it should be even with the bottom of the opening, but I will double check the FSM. There is a drain plug lower for changing oil. The oil I pulled out of mine had some black coloration. New OEM oil is amber.

I've always run OEM LSD gear oil in my Monteros. 20k miles since diff swap and fluids.

https://www.rallysportdirect.com/part/lsd-oil-and-additives/mit-mz320345-mitsubishi-diaqueen-gl5-lsd-gear-oil-1-qt

The FSM specs. GL-4 for the transfer case. (The diffs. call for GL-5.)

 

[122andy]

I changed t-case oil yesterday. Nothing out of the norm with the old stuff, a little bit of gunk on the plug magnet, nothing crazy. Didn't make a difference in shifting tho.