4wd - I Broke It Properly Now!!!

[ICEMAN2000]

Why do so many threads just stop with out any mention of a conclusion.

I have the same problem, in that when I press the 4wd button nothing happens as I can still turn the front prop shaft. in fact when i move the lever to low range I can still move the front shaft. What is my problem or to put it a better way.....how the hell do I fix it ?

[angelonawire]

Same problem as me by the sound of it

I'm going to strip down the engagement motor on the transfer box. It would appear that this is a relatively common fault so that is where I will start when I get home a week tuesday.

[angelonawire]

4WD snag sorted

Well, you'll all be glad to know I've found the snag and sorted it, see attatched pics, due to the breather pipe being perished the water had been getting in causing this



Pinched the one off my old 2.4 and it now works a treat

[Hazzo]

Why do so many threads just stop with out any mention of a conclusion.

I have the same problem, in that when I press the 4wd button nothing happens as I can still turn the front prop shaft. in fact when i move the lever to low range I can still move the front shaft. What is my problem or to put it a better way.....how the hell do I fix it ?

Probably because they gave up and took it to the scrapman/Stormy, some things on these are a right pita and I keep thinking of scrapping this one, then it snows and everything in the world is rosy. H

[ICEMAN2000]

Angelonawire,
thanks for the photos, can you tell me if this part can be removed in one piece and is there any loss of t/box oil when removing it? If it can and if there is no oil loss I thingk I will do mine this weekend.

[angelonawire]

Iceman
If you remove the cables and the breather pipe, then 4 x 10mm bolts on the passenger side of the transfer motor, you can then remove the cover to the transfer box pinion gears. Carefully prize it of, there is a thin rubber gasket between the cover and the housing, and you will lose a couple of teaspoons of transfer box oil, not enough to require a top up as it will be refilled from the transfer case when you start her up.
Inside you will find 2 cogs/ gears the larger one engages the pinion shaft, pull it out with your fingers, remember which way it comes out. Then remove the 3 x 14 mm bolts holding the motor assembly onto to the transfer case.

Job done!

Next you get to clean up the the contacts on the opposite side, 3 x10mm bolts, rubber gasket, no oil. Be careful if you remove the toothed gear inside to clean up any corrosion as it has to be put back exactly as it came out.

Have fun!

[ICEMAN2000]

Angelonawire,
Thanks for that, I have removed the three bolts (10mm socket) and prized off the cover, marked and cleaned the contacts etc. I have also removed the three (12mm bolts) which hold the unit to the t/f box. i am unable to remove it however due to the shaft from it going into the t/f box. Is there a knack to removing it If I can get it out I will be able to clean the electric motor as well.

[ICEMAN2000]

I have also read that when pressing the 4wd button on the shift that relays can be heard, I dont hear any. Should I be ?

[angelonawire]

you have to remove the cover on the opposite side 4 x 10mm bolts, there are two sprockets/gearwheels in there, pull the top one out with your fingers. this will allow you to remove the unit from the transfer box.

you should hear the relay when engaging 4wd 4L on the transfer lever, you will hear the relay for the 4H button if and when you fix your motor on the transfer box

[ICEMAN2000]

thanks, and my apologies for not responding sooner. I now have a replacement unit and will be attempting to fit it soon. Please tell me should the tranfer box be in two or four wheel drive for its removal ?