I just logged in to ask about the 4x4 lights suddenly blinking and the transfer case engaging when I saw the second previous posting. Must be sunspots?

Montero XLS, 2002, 73K miles. Never had this problem before. Merged into traffic at about 30 mph and as I was slowing down for trqaffic ahead, I realized the front axle was engaged - I could hear the gears turning since my windows were down and I was under a bridge. I thought I accidentally engaged the case so I looked at the shifter which was in the 2H position, then immediately looked at the dash lights and saw the front wheel lights flashing.As I was slowing down to stop, the gear noise was also slowing down consistent with the speed of my vehicle and just before I came to a stop, the axle disengaged - I heard a thump and it felt almost like someone slightly rear-ended me. The dash lights kept flashing but the case seemed to have disengeged. I moved the shifter into 4H - this made the dash light stay solid, then shifted back to 2H. Dash lights went out. All ok for about 30 minutes until I was slowing down again and the same thing happened - suddenly hear the gears at about 25 mph, front wheel dash lights flashing, down to 5 mph - thump - case disengages but light continues to flash on dash until you play with the shifter.

Read previous posts. How hard is it to clean up the switches on the transfer case? How hard is it to change the freewheeling switch?Where are these two devices located on this particular model? Anything else to look at? Thank you all in advance.

Jay

 

Jay,

Seems to be a semi-common problem although frankly I'm on several forums and this one gets mention of it way more frequently than the other ones where it's mostly off road drivers who post up questions. You figure it would be the other way around.

 

I am having the same problem with my 2002 xls it has 83k miles I changed the gear oil and disconnted the freewheel switch this made the front blinking lights go out but once in a while it still tries to engage. The freewheele switch is next to the actuator near the front diffrential. You will need to remove the guard that covers the diff and oil pan and then you can see it. From reading here the switches on the transfer case are located on the top of the case and to gain access you will need to drop the case down. I think my next step is to disconnect the two vacuum hose that activate the actuator for the hub to lock and see if it stops trying to engage.

 

Isnt wheeling a GENII pretty rare anyway? Maybe this issue is related to the switches used on GEN III units and it not talked about as much due to most guys running older trucks?

I try to engage all 4 positions on the shifter every few months - if anything to "exercise" the 4wd system - since my 62k 03 is on road 95% of the time. No blinking light problems - YET....

 

Just curious for the guys with blinking light problems - do you ever take it out of 2wd mode? Maybe its a lack of use thing? It would be great for someone to figure out why some have this problem and others do not...

 

Yes and no. I see plenty of Gen II rigs that are dramatically more capable than most Gen I's (I own 2 gen I rigs). About the biggest advantage a Gen I is the 2door v6 model because of it's short wheel base. Aside from that rig, I'd take a 94-96SR any day over most any gen I rig. The 94-96 SR's have significantly stronger drivetrains over the Gen I's and come with a factory rear air locker and lockable xcase. Plus you can easly perform a few moderate upgrades (2" Suspension lift, 2-3" body lift, 4.9 R&P gears and 3:1 xcase gears), and your able to run 37" mud terrains.
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You can't do that with a Gen I. Just not enough power to use them effectively offroad. The largest you can run are 35's w/ a similar set of upgrades (all same except a 3" body lift is manditory and 5.29 R&P gears and 2.95:1 x-case gears).

But, I gotta say I love the look of my gen I over a Gen II or Gen III for that matter.

 

I drove my 2003 Montero with that noise & clunk for 6 months -4WD light flashing. Changed transfer case switches and 2 were bad(not opening) . Noise stopped but light was still on. After 9 hrs of diagnostics mechanic confirmed my fear- I put 2 switches into wrong holes. You instal those by feel (no access unless you drop the case completly).
So if you don't have the shop manual replace switches one by one . Now my system works and switches, BUT in 2WD after few minutes the noise and clunk is back and on the highway the light starts flashing!!!!! Only in 2WD , there,s no problem in 4WD.
My mechanic said the system shows no problems. He's 2 hours away so I will try disengage vacuum hoses to see if it helps. Freewheel switch is fine and hoses look fine too. My next step is replacing the solenoids. meanwhile I drive in 4WD.
One last thing -the system is trying to disengage not engage ( i think) because the safety feature in default mode ( when transfer light is flashing) keeps it 4WD. Paid $360 for 5 switches but you can easily check them with ohmmeter for continuity and find the bad one. Hope it helps and I will let you know when I fix this problem . I was all fine for 7 yrs and 180000km ( 112000mi).

 

I too have this issue, when first bought vehicle had it fixed was told it was a fuse was not expensive at all . a few years later same issue different dealer , now very expensive........ soooooooooo still blinking.