Frozen (transfer case) Lever
Hello All
I recently purchased a 1999 IO, I was hoping to re register it,but Alas Too many kilometres on the sand and the rust has won.
It will be a good farm vehicle on my small property.
I have tried to engage Low range with no success and am confident it is now stuck in 4wd High, because it takes more revs to take off and gear stick is not at rear position for 2WD
NB Indicators lights on dash show top two illuminated.
After reading comments & suggestions on this forum, I have removed selector lever to inspect the bal l/ Bush assembly.
Am I correct in assuming the ball bush assembly is held in place by the Pin ??? there are no remains of a ball / bush assembly and the pin seems to move from the slot in the metal case
This may be the issue for a stuck lever
Can you please provide advice for a new IO owner on the stuck lever & indicators lights ???
I don't guarantee ...
I don't guarantee that this bush will fit, but I believe it will - when I got my car, like yours, the bush had disappeared, I made one from a polyurethane shock eye bush - sanding it to the shape and size I thought it should be.
The cross pin restricts the fore/aft movement of the transfer case lever and the ball allows the left/right movement - there's also a "shift gate" at the top of the shft tower that restricts movement - you have to depress the lever and then go left and forwards to be able to select 4L - without the bush it's going to be very imprecise and you'll have to fiddle around.
If the lever is not in the 2H position, it's normal for the front two indicators on the SuperSelect dash display to be lit.
Thanks
Thanks for your help, Claude & Fordem
I have ordered a Ball / Bush of the site suggested by fordem (they claim it will Fit) so when it arrives and I reassemble I will let you Know the out come.
Fordem The two green lights at the top of the display are normal in 4WD.What does a flashing lock light indicate ?? ( Yes I had a play with a couple of screw drivers in the Transfer case while lever removed.)
While I am at it I will change TF oil, any suggestions on what oil I should use
A flashing lock light ...
means that the 4WD indicator controller thinks there is a problem with the center "differential" lock - there are two switches on the transfer case (there are five in all, but two are for the center lock) that monitor the operation of the center lock, one monitors the lever selection and the other monitors the lock position if they don't match the controller flashes the light - if both switches say "unlocked" the light will be off, if both switches say "locked" the light will be on, anytime one switch says locked whilst the other says unlocked, the lights will be flashing.
Please note that I said the controller "thinks" there is a problem - it could be a defective switch - it could be a broken wire - it could be that the center lock has not locked or unlocked - in my experience you some times need to "rock the vehicle" slightly to get it to lock or unlock - the vehicle should be stationary and in neutral when selecting or deselecting 4HLc or 4LLc, and I sometimes find it necessary to shift into D or R (my car has an automatic transmission) momentarily to get it to lock or unlock.
For what it's worth - I had a flashing lock light anytime I tried to select a 4WD position when my car had no bush - it turned out to be a broken wire.
Oil - the manual calls for 2.2 litres of SAE 75W90 or 75W85 GL4 oil - GL4 oils can be hard to find, a "yellow metal friendly" GL5 can be used - the difference between a GL4 & a GL5 is the EP or Extreme Pressure additive pack - GL5 oils have more EP additives. Some GL5 oils use sulphur as an additive and the sulphur attacks brass and bronze - the so called yellow metals - I use Mobil One full synthetic 75W90 GL5.
Syndicate
lever
You are 100% correct, that bush goes where that pin is, you will find left over when you change the oil of the T/C ! The problem is that Mitsubishi do not sell the bush only but the complete lever mechanism ($$$)> Other (Fordem) have made their own and someone else have found a replacement...somewhere in the forum or they will mentioned it shortly here, I am sure.
For the light, it could be a few thing, but I would first check the switch on the T/C, their are 5, 2 at the bottom, one of those 2 might be H/S.
Happy io
My io is now SOLD Thankshttp://pajerio.com/forum/claudes-io-2002-zr-built-thread-onlyhappy-io