pmontero
Roll Me Over
Reged: 07/12/01
Posts: 3167
Loc: Peachtree City, GA USA
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Hi,
I replaced both 4wd switches in my transfer case this afternoon and thought I'd share my experience.
This is not a difficult task, but there are a couple of expensive parts needed. The only reason to replace these is if your 4wd indicator light no longer illuminates when you shift into 4wd. One of my switches had both leads torn off and the other was in pretty bad shape. Also, both steel balls were missing from behind the switches. Make sure you order the following parts to do this job:
MD704162 4wd switch(male/male) $27.43
MD704163 4wd switch(male/female) $27.43
MF660034 switch gaskets (2) $.08
MF540010 steel ball (2) $.53
Tools:
12mm socket for transfer case skid plate
19mm deep socker or open wrench for switch removal/tighten
Remove the transfer case skid plate by removing the 4 screws holding it in place
Remove the two lead wires from the switches and disconnect the two leads connected between the switches making note of their orientation.
Carefully unscrew one 4wd switch at a time making certain to notice which one has a male/female connector and which has two male. If you suspect that the steel balls are missing from behind the plunger in each switch and plan to reuse the existing switches, be careful not to damage the leads while loosening the switches with a wrench. You may be able to use a deep socket by folding the leads and inserting them up into the deep socket wrench as you place it down over the switch for removal.
As you remove the switch from the socket be careful since the steel ball, if there, will fall out of the hole. Now, place the steel ball up into the socket, place the switch gasket on the switch and carefully screw the switch back into the socket. This takes some maneuvering to keep the ball from falling out as you insert the switch back into the socket. Repeat for other side.
Reattach leads on switches and replace skid plate. You should be ready to go.
Powell
[ February 24, 2003, 11:07 PM: Message edited by: pmontero ]
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'87 Montero Diesel
'98 Porsche Boxster Electric
and more...
Greasology
NotPetroleum
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Geophie
Body Damage is Cool
Reged: 08/21/00
Posts: 1273
Loc: Elkins/Goshen, AR USA
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Thanks, Powell
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1991 4dr RS, ATK 3.0, auto. Now with zero trans fats!
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off-roader
Mitsubishi Forum Moderator
Reged: 01/16/00
Posts: 15504
Loc: Bay Area, CA
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Archive Please...
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Off Roader
96SR (3.15:1 xcase, 35's), 89 V6 SWB (33's)
96SR Build Up Thread
Old web page
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IdahoJack
Mudrunner
Reged: 01/09/02
Posts: 457
Loc: Weiser, Idaho
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Powell, do you know which switch is the "4x4 engaged symbol", and which is the "wheels locked"? My "wheels locked" switch works, but the other one doesn't.
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90 Montero, 2dr, AT, V6, LSD, AC, KYB shocks, bouncy seat, 182K miles, JDM engine, 87 Starion seats, tow hitch
http://www.geocities.com/idahojack03/Index
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DougH
Mitsubishi Forum Moderator
Reged: 02/25/01
Posts: 9781
Loc: Putnam, CT
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I dont have this problem but I am curious... where do you think the ball went?
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DougH
1995 Sr. High speed dirt!
www.terminalstills.com
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pmontero
Roll Me Over
Reged: 07/12/01
Posts: 3167
Loc: Peachtree City, GA USA
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quote:
Originally posted by IdahoJack:
Powell, do you know which switch is the "4x4 engaged symbol", and which is the "wheels locked"? My "wheels locked" switch works, but the other one doesn't.
Jack,
This post is to fix the "4x4 engaged symbol." The "wheels locked" symbol is controlled by the pulse generator in the t/c and also has a switch screwed into it with leads. However, that one is more complex since I think there is also a relay under the dash to control this.
Either way, you either have a disconnected/damaged lead or the steel balls are missing from behind the switches. (the light will work with one ball missing, but it'll either be dim or won't go out completely depending on which ball is missing. (I guess you could also have a burned out dash light)
DougH,
They don't have any place to go unless someone unscrewed the switch and let them fall out. This is a common problem if you have the t/c rebuilt. (that's when both of mine disappeared)
Powell
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'87 Montero Diesel
'98 Porsche Boxster Electric
and more...
Greasology
NotPetroleum
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fasteddy
Web Wheeler
Reged: 01/30/01
Posts: 12705
Loc: Flat Creek, GA
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The two switches control the 4wd light and the low range light. The locked light is controlled by a magic box on the passenger footwell outer wall behind the glovebox which takes signals from the pulse generator on the rear of the driver's side of the transfer case and from the reed switch in the speedo.
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"If you can't be a good influence, don't worry, you can still be a horrid example."
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Pastor
Wheeler
Reged: 11/11/03
Posts: 180
Loc: Gastonia, NC
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Quote:
MD704162 4wd switch(male/male) $27.43
MD704163 4wd switch(male/female) $27.43
MF660034 switch gaskets (2) $.08
MF540010 steel ball (2) $.53
Where in this universe can I find these parts?
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91 Montero LS, LWB, 33X12.5X15 BFG MT on 15X8 Rock Crawlers, Budget Lift, Roger Brown 1" body lift, Custom Uwharrie rocker panel dents
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FrankR
Web Wheeler
Reged: 02/01/04
Posts: 10225
Loc: Columbia, SC
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Quote:
MD704162 4wd switch(male/male) $27.43
MD704163 4wd switch(male/female) $27.43
MF660034 switch gaskets (2) $.08
MF540010 steel ball (2) $.53
Where in this universe can I find these parts?
Since you already have prices, I assume you've been to a dealer. Here are the prices from a discount dealer network:
MD704162 - $21.58
MD704163 - $21.58
MF660034 - $00.06
MF540010 - $00.42
http://www.mitsubishiparts.net/
Plus shipping, of course.
Frank
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'89 G-Raider Supercharged 3.0L, MegaSquirt 2, lockup A/T, 2.5" exhaust, 155k, Cibie H4s/Oscar SCs, Hella Micro DE fogs, Cobra CB, Superwinch hubs, LSD rear/Aussie Locker front, Bilsteins, 165A alt., Lifeline AGM, Rust-Oleum
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LRJ4x4
Web Wheeler
Reged: 12/17/01
Posts: 11717
Loc: Monterey, CA
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Those a Mitsu Dealer part numbers, they start with MD. You get them from the dealer. Most likly your local dealer will not have them in stock and they will have to send out to the "Warehouse" It take a day or so. If I order at my dealer before noon I will have it the next day.
They will not tell me where this mysterious warehouse of goodies is located but I have dreams of winning the lotto and buying it 
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98 Montero with cold weather package
96 Toyota Land Cruiser, fully locked Mall Machine :-)
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