Still Stuck

[james-r]

My surf is still stuck in 4wd, just changed the vac pump on the alternator, checked all the vac pipes and all is well, getting good vacuum from the alternator itself, all the pipework into the innerwing and backout of the innerwing.
Now i dont know the ins and outs of the system but the solonoid on the front diff has vacuum going to it but not away from it and there is no vacuum to the solonoid on the back of the t/box.
Also im getting no clicking when i press the button on the transfer lever, but the relay under the steering column clicks when i move the transfer lever.

Any advice is gratefully recieved as im at my wits end now, luckily the wife is off work so i can use her car but the surf has been off road for over a week now.
cheers james

[NiftyNev]

The transfer shift motor is electric, there's no vacuum to the transfer at all. What you are probably looking at is just the vent hose for the motor.

There's two VSVs associated with the front diff on inner wing. Front one activates the ADD rear one disengages it.

Nev

[james-r]

should i be getting vacuum both to and from the solonoid on the front diff as im only getting it one way, what about the no clicking when i press the switch on the transfer lever.
cheers, james

[Albannach]

There are 2 Vacuum supplies to the actuator. One to engage, one to disengage. The supplies come from the VSVs as Nev has pointed out.

So at any one time, you will only see vacuum at one hose, switch the 4wd button and the vacuum will switch to the other hose.

If you have tjhe hoses mixed up, the actuator will be engaged when you select off and disengaged when you select on. The vacuum does not switch 4wd, that's done electrically.

There are no vacuum supplies from the actuator, only to it.

[james-r]

Thanks for that, its made things a bit clearer, the hoses were taken off one at a time so cannot be mixed up, the 4wd will not switch off so i cannot check if im getting vacuum from the other pipe.
This is why im thinking its more of an electrical problem as it wont switch off and no clicking from behind the radio area like it used to do, could it be the 4wd control unit that has packed in? when i plug and unplug this the little cylinder shaped relay clicks under the steering column.
thanks again, james

[JUDWAK]

if ya need to look at a 2.4 iam not too far if ya want to compare to mine
if it helps giz a ring

[NiftyNev]

To confirm that you are getting voltage to the two VSVs.
Grab a multimeter.
Disconnect both VSV plugs.
Turn ignition on and press button.
Check for voltage at rear VSV plug. (Should be blue one)
Release the button and check for voltage at front VSV plug (Should be brown)

No voltage at either indicates a problem before the VSVs.

If voltage is ok reconnect and with engine running check for vacuum at the VSV with the blue plug by disconnecting the hose (which should have a blue band) to the ADD Actuator on front diff. If vacuum is ok there reconnect and check that this hose is connected to the front of the ADD actuator and has a vacuum.

The other VSV (with brown plug) should have a hose with a white band and be connected to the passenger side of the ADD actuator. Test for vacuum with the button out in the same manner as the first VSV.

Nev

[NiftyNev]

There's two VSVs associated with the front diff on inner wing. Front one activates the ADD rear one disengages it.

Nev

Read previous post as I may have posted wrong info regarding which VSV does what.

Nev

[james-r]

Right here goes, checked all the plugs on the front and rear diff all reading good voltage, checked the two plugs on the inner wing (are these the vsv's?) i have a blue and a brown plug,

Blue plug reads 13.7 with the button pressed in or out with vacuum on the top hose but not the bottom hose.

Brown plug has no reading at all with the button either in or out with vacuum on the top hose but not the bottom hose.
when the units get moved there is a clicking and the voltmeter goes up then back down but never enough to stabilize this is from the blue side only
does this shed any light for anyone
cheers, james

[james-r]

As there is no power to this plug does this mean that the little black box of 4wd magic under the radio is buggered? or is there something else to look at?
cheers again, james

[james-r]

Resurecting this old thread as i still have the problem.
I have replaced the 4wd control box and the 2 vsv's (Cheers Brad), its still stuck in 4wd but now if i unplug the 4wd control box it disengages the 4wd system and it can be then switched back on with the button on the transfer lever and again if i unplug the box it switches off again, had all 4 wheels up and it actually stops drive to the front wheels.
Anymore thoughts to my problem are appreiciated, but be quick bonfire night is nearly here and it could go on top.
cheers again, James

[Albannach]

Have you replaced the 4wd control box?

[james-r]

Yes and the vsv's, it didnt switch off at all with the old 4wd control box unplugged just stayed in 4wd all the time, thats why i ended up taking the front shaft off, its all back together now though.

[BUSHWHACKER]

Sounds like the problem lies with the button/switch on the shift lever.

[Albannach]

Yes and the vsv's, it didnt switch off at all with the old 4wd control box unplugged just stayed in 4wd all the time, thats why i ended up taking the front shaft off, its all back together now though.

Sorry, I sent my question before I'd finished it

Did you replace the box thingy with a known good one?