Outer Limits 4x4 Board

Hi,

I know this comes up every now and then.

I am now experiencing the problem.

I used my vehicle in super-select 4WD this week-end - No problem. Came back on highway and slowed down to 120km/h, pushed it into 4wd and the indication lights kept on flashing. took it out and in a couple of times but the lights don't stay on. Tried again this morning, but problem still there.

Where can I look for the cause? I only launched a boat, so no chance of anything to go wrong under the vehicle like mud etc.

Willie Purchase

i've found in a later model same specs paj that the lights flash for a while. how long did you leave it in 4wd for before changing back to 2wd?

I left it flashing for about 10 kM's. This morning comming to work it kept on flashing from the moment I left for work and then parked the car about 20 minutes later. So it ain't going to stop flashing in 4wd. when I go into 2wd, then it does go off though.

WP

A couple of things with the super select system.
Whatever the position of the t/case lever that is the gear you are in, it is a mechanical function.
If you have flashing dash lights :-
- orange centre diff flashing light is an electrical issue with the centre diff detent switches on the t/case, possibly a broken wire or a short, could also be a dodgy connection due to mud. There are 3 centre diff detent switches on the t/case.
- green flashing lights indicates that the free wheeling hub is not locked/unlocked (located next to the front diff). Possible causes are mud/grime build up on the the boot not allowing the piston to move freely or jamming it up. The other cause can be a vacuum hose leak, there are 2 vacuum hoses located on the right side inner guard that allow engine vacuum (via solenoids) to the free wheeling hub to engage/disengage when it gets the signal.
Check for vacuum leaks there, also could be a dodgy connection from one of the sensors (either on the free wheeling hub or the t/case) or even a cactus sensor.
Very rarely does it turn out to be the 4x4 ECU (located behind the dash).

Frank.

I assummed you already tried going forward a few hundred meters then reverse for a few car lengths, do it so the car jerks a bit and do it a few times.
The super select function needs to be used regularly to keep everything working.
When I first got mine I had real bad binding problems (and the flashing lights) as though the viscous coupling/centre diff was really stiff causing wind up. An oil change and regular use and I've never had a problem with a lot of offroad driving, mud etc.

After going through the system methodicaly, I have found the problem.

My 4wd does engage, all vacuum is ok solenoids function as the should, but the 2/4WD position indicator switch on the transfer case does not function right.

When I bridged it out to earth after selecting 4WD, the lights stoped flashing.

I have now been waiting for more than a week for the part from the local dealer. They have given me 2 wrong parts so far.

They reckon that there isn't a switch for my vehicle in the country. So the have tried the Colt Rodeo parts and also a 98 Pajero's switch.

But at least I have learnt how the system works and that all is OK except the indication.

C

Willie

I solved the problem eventialy.

The real one this time as it turned out not to be a faulty switch. ( but it was the switch not being able to change state)

Just to let you know what the cause was in case it might help someone else.

The 2W/4WD switch on the transfer case was actually OK. The switch has a plunger that pushes onto a steel ball in the hole on the transfer case. The steel ball then must drop down into a recess on the shift rail when 4WD is selected.

Now this steel ball was stuck so that when I shifted to 4WD it could not drop down into the recess. Thus the switch could not change state. The force of the plunger was not strong enough to push the ball down. Allthough I loosened the ball it kept on getting stuck.

Solution; I installed a spring which just fits over the plunger of the switch to assist in forcing the steel ball down when I shift to 4WD. Now my indication lights are working fine. It actually changes state much quiker than before.

Might be of use to someone else.

Willie
South Africa