Outer Limits 4x4 Board

Hi guys l have fitted manual hubs and changed the ADD diff for a Hilux front diff with no ADD.

The problem is l joined the 2 wires together that went to the detection switch on the diff when joined the 4wd light comes on with the button pushed in or out, and then can't get it to turn off.

Also now l can't get it out of 4WD as the front tailshaft is spinning all the time instead of being disengaged in H4 button in or out.

Not sure what the problem is, l have seen mentioned on here about the 4WD fuse 20 amp but cannot find it. Also have blocked off the vacuum lines for the ADD not sure if this would cause a problem.

Please help l need it fixed by tonight as going out tomorrow morning with a big group and it sucks if l can't go as l am the organiser.

Cheers Chris

If you tested it on sealed road sometimes you have to reverse back a few metres to get it to release due to windup. Try turning 4wd off and reverse back a few metres to see if the light goes out.

The computer works it out like this.

When you press the 4wd button it locks the transfer in. It has a synchro so spins up fine. Once that switch detects it is engaged it triggers the vacuum solenoig to lock in the ADD. Once the ADD is in the switch on it tells the computer it all happening, and lights the dash.

Unlock is the exact reverse. If it thinks the diff is still locked in, it won't unlock the transfer case. It insists on the diff locking / unlocking first as it has no synchro's and the vacuum actuator is not particularly forceful.

I dont have a wiring digram to figure out how to bodgy it, and if the control system is electronic or relays.

One way would be to fool the thing by routing the switch to the interior on your dash, but that's not a particularly elegant solution.

The Yahoo Surf list may have more info. Personally I liked the ADD system despite early misgivings.

Paul

fixed it it turned out to be a stuck 4WD activation pin on the transfer case, removed and refitted works fine now.

Thanks Chris