Diagnosing and proving how Pajero/Montero 4WD actuator solenoids work

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** Disclaimer: I had a bad cold when making this video and man, did I get some stuff backwards. Fundamentally what I say in the video about how the system works is correct, but when I talk about when solenoids are on or off based on a voltage reading, or the front diff actuator rod is in or out, I may have it backwards. Sorry folks. **
Following on from diagnosing that my 4WD "Super Select" aka "Active Trac" 4WD engagement solenoids are the root cause of 4WD engagement issues on the NL Pajero, I decided to dig a little deeper and see exactly how these buggers work.
It's actually a really reliable system (aside from those dang solenoids LOL). The control box does very little other than tell you whether it thinks 4WD is working properly, but you could literally remove the control box completely and, assuming the solenoids and vacuum lines are OK, have a fully functioning 2WD/4WD selection system.

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5 окт 2024

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Комментарии : 62

@scottfellers1943 Год назад

I love how in depth you went on this. Not only showing how to fix the problem but giving a really nice demonstration on how the 4wd system works. Some of us really like to know the "why" behind what we are doing, not just blindly replacing parts. Really great work!

@po8468 2 месяца назад

Most helpful video of the SS system I have been able to find. Nicely done and thank you.

@yavuzcamo6019 Месяц назад

Great effort mate. Btw the diode is required in almost all circuits containing a coil to limit/block the back voltage generated when the solenoid is powered up/down just like in 3-phase dc motor drive circuits, oddly called a freewheel diode (no relation to freewheel clutch).

@EVERYTHINGOVERLANDANDUNDER 4 месяца назад

Thanks for the video mate.... Helped me on a 2018 Triton to get my head around how Mitsubishi did this... 2018 was obviously more involved, but basic thought process was the same

@eugeneclarke672 Год назад

That's a brilliant explanation of the 4x4 system. Thanks for posting

@johnrickard4326 Год назад

Great video bro. Sorry to hear about sleep apnoea, hope you get on top of it. My 2005 delica auto has locked up all wheels, had to skull drag it to mechanic only for them to say its not the diffs or transfer case and I need to buy another auto. No mention of solenoids until I asked them were they checked. Then of course they said yes. I am very suss if they were checked. It wasn't on the bill either. Now they want it gone and I have to pay for another tow to get car home in same condition. The guys at delica garage said it could be the solenoids but I am in Cairns with no one here I trust. Only been here a short while. Anyone else had this experience? Any help would be appreciated. Cheers.

@DanielNicholson-sb9tc 11 месяцев назад

Bro I'm 40 and had the same yarn with the sleep apnea.. Anyway long story short I started doing 30 mins cardio and dropped to low carb beers... didn't have to give up the piss but it cured my sleep apnea 😅😅

@woden20 Год назад

THE Best video on youtube showing how it works. 👍

@bigfich123 Год назад

Great video. I replaced my solenoid and it still doesn’t want to engage 4x4. If I unplug the solenoids I can trick it into engaging 4x4 which is odd and vice versa. Have left it in 2H for about a year now as gave up on it. But this video has given me insp to try fix it again

@gjcarr2991 Год назад

The old flashing issue...yeah sorry fixed my issue as well...as long as I can get it into 4wd when I go to Fraser I'm happy...any way great vid mate, well detailed and grey explanation l.....also yeah CPAP machine changed my life too.....keeps those vids coming

@firecrackerg60 2 года назад

Good video... hope this is my issue. At least i understand it a whole lot more now. Appreciate your effort in making this clear and informative 👌

@KaldekBoch 2 года назад

Thanks. I could do better but I often lack the time.

@Scottadamsfan3481 5 месяцев назад

Yes I agree about the breathing issue, oh he also solved a car problem as well

@ietifindingsolution 2 года назад

I have same issues in my 2000 Mitsubishi pajero it siting for 1 years now I plan to fix it soon thanks for video 📹.

@KaldekBoch 2 года назад

Cheers mate. The switches in the transfer case and on the front diff may also need cleaning. My NH Pajero which I'm selling to a mate needs the switches cleaned up. Contact cleaner is your friend there.

@robinodell9453 2 года назад

I think the diode is fitted to help with the power dissipation when the solenoid coils are de-energised. Common practice in industry.

@KaldekBoch 2 года назад

Thanks mate, I don't think I would have picked up on that.

@finnmckechnie3901 Год назад

Thanks for this video mate. Super helpful and great in depth explanation

@edwardmorrison2461 Год назад

Same problem on MK. Disconnect the vacuum hose from the solenoid and 4x4 engages.

@mikebishop532 2 года назад

good shout out on the apnoea. the sleep study changed my life too

@cyclopsfpv247 2 года назад

Thanks for the vid! Been looking for answers to this flashy light problem for a while now. I pulled my solinoids out and tested them on 12v. They seemed OK, but still having issues with lights flashing when putting it into 4H. It does engage though, so must be the detection switch that is dodgy.

@KaldekBoch 2 года назад

Yeah this is just a reminder that what I really need to create is a video which has a flowchart that goes through how to diagnose the cause of flashing lights, as there's more than one reason why they flash.

@KaldekBoch 2 года назад

Also I just put a set of solenoids in my other Pajero (the NH) and it also still has some issues, so it also obviously has some issues with the detection switches. I'll start with the switch on the front diff as that is the logical next place to look,

@timothykwillick Месяц назад

Hey mate amazing video. I have an issue when engaging 4HLc and 4LLc.. between 2wd and 4wd is fine, the control box lights all work. but when I go to 4HLc and 4LLc, I get instant error code flash? although the 4HLc still definitely works mechanically as you say. (I don't thing low range engages) I have replaced the vacuum solenoid. What do you think my issue could be?

@riverinabarter-lm4si 5 месяцев назад

Oh wow that 😢 never head of awake apnea it sounds like my son x I'll get him checked out

@alansookraj3501 Год назад

Great video

@PeterLehmann-i3p 7 месяцев назад

Hey mate, where did you get the electric schematics? Great video!

@Scottadamsfan3481 5 месяцев назад

Airbox clips broke is probably why they did those screws

@Scottadamsfan3481 2 месяца назад

My 2006 Montero is making a loud whirring grinding noise when I slow down and turn like when I get into my neighborhood.. coming from front right side Is it possible my 4wd vacuum silenoid is messed up so it’s like trying to engage in 4wd ?

@a.jabali6490 2 месяца назад

Hi .. this thing happened to me two days ago , I changed my gear from 4H to 2H and the front tyres lights keeps flashing non stop , If I put back the gear to 4H or 4HLC or any gear it works fine as normal , but the 2H gear refuses to engage back to normal even If I drive for a long distance it keeps flashing .. and yesterday I heard a sound like friction .. I changed the solenoid 9 months ago .. have you faced this issue before ?

@KaldekBoch 2 месяца назад

Yeah it will be this system. Either the solenoid setup or one of the vacuum lines has failed.

@willy37392 5 месяцев назад

Ser, Can i have a copy of this electrical diagram montero V78, my car in trouble with this motor actuator in transfer case. Not respon if i switch 4wd handle. Thank you

@Mrveescuba Год назад

Hi there i have shogun/montero/pajero 2004 did..and it start flashing orange when i turn off the ignition ans start the car again many times went off and everything works as it should!!couple of days now and the flashing ligth came plus another 2 ligths top left i think is antispin or something..any idea if its about solenoids? or trasnfer case swich??thanx for the vid anyway

@pierogillio Год назад

I have no voltaje on the selenoids conector, any idea if there is some fuse??? Voltaje show 0,01 but it has continuity

@traveldiaries6078 10 месяцев назад

Hey mate I got same 6g72 engine 92 paj hard to start on the cold intake any idea changed lot of things spark plugs ,0z sensor ,throttle body ,fuel pump ect

@82acresfarm Год назад

Whats the part number on that solenoid?

@bigfich123 Год назад

So my issue is that 2H works, changing into 4H the solenoids don’t turn off and it doesn’t engage the front diff and continues flashing. I can manual engage 4H but unplugging the solenoids. So would this be the 2-4 switch or the free wheel switch

@Siegrfield85 Год назад

My pajero blinking the front wheels when 4x2 is activated ... can you help me ? Plz

@thomasmacokatic6219 Год назад

got the same problem. 93 td im gonna try swap that part and spray switches like he suggested in a earlier comment response. lemme know if u fix before me :)

@thomasmacokatic6219 Год назад

hey man i literally pulled the vacuum switch plugs out like he showed in this video and cleaned with contact spray and the lights stopped flashing immediately after :) hopefully stays good, just thought id let ya know

@xrotor7813 2 года назад

Great in depth video - I have a 2002 Montero in Canada and have an intermittent issue with the flashing center diff light too. However I just have the flashing center diff light after 20-30 km of relatively high speed driving. If I am driving around locally (slower in traffic) then I never get the error. I am guessing that my leak is small and only ever produces the error when engine vac drops under load for an extended time when the vac tank is depleted as well. Does this fit with anyone else's experience?

@KaldekBoch 2 года назад

Your flashing center diff light - does it come on when you're in 2WD mode or 4WD mode (only) or regardless of that setting? Most likely your issue is a sticking centre diff lock switch on the transfer case. I need to make a better video on the overall system but the majority of the Active Trac/Super Select system is totally mechanical based on the transfer case lever and its associated forks that engage gears in the box itself. The rest is all just microswitches which dictate what lights flash on the dash.

@xrotor7813 2 года назад

@@KaldekBoch the flashing center light only shows when driving in 2WD just like in the video. I had a spare freewheel control in the tool box so I just swapped it to check.

@KaldekBoch 2 года назад

@@xrotor7813 In your case I would remove and clean/test all of the microswitches that connect into the transfer case. I suspect that will be the root of your particular issues.

@drtone Год назад

so by swapping vacuum lines, u could get 2WD lo ( lever positions changed :: 2h=4h, 4h=2h, 4hlc= 2h, 4llc= 2l)

@KaldekBoch Год назад

Do you mean changing the lines so they're in the wrong place? I suppose you could do something wacky like that, but why?

@drtone Год назад

@@KaldekBoch Yes, purposely swapping them in wrong place. Reason why is I have Pajero EVO and can do over 110 kph/70mph well below redline in 5th gear(auto) in 4llc for aggressive rally cross and off roading. The torque multiplication makes truck feel like 400hp(?) I want to be able to select low gear in transfer case, but be in RWD only, and AWD( ie open center diff 4lo). Ideally, it would like to retain traditional 4llc for self rescue, I think it should work, i suppose additional vacuum solenoid plumbed in could make ultimate systems. maybe paddle shift actuation

@drtone Год назад

Does 4llc happen in the transfer case,,,,,and the front vacuum actuated axle connector not involved?

@KaldekBoch Год назад

@@drtone Ah I don't think that would do much. The Low and High is a mechanical setting via the 4WD lever in the cab. The solenoids don't do anything other than control whether the front diff is engaged or not.

@KaldekBoch Год назад

@@drtone Correct. The vacuum axle connector ONLY engages whether the front axle is engaged. The transfer case controls the Low/High ratio mechanically.