Isn't this freaky.....
 

Found the ground strap (transfer case to floor pan) about 90% worn through from rubbing on the exhaust clamp. Could this be the problem? Usually weird electrical stiffcould be attributed to grounding problems. Comments? Or is this grounding strap just to prevent radio interference? Going to replace it, just wondering what the forum thought. See original post below.

RE: Isn't this freaky.....
 

Why didn't you just post this in the same thread?

RE: Isn't this freaky.....
 

Didn't get to many hits on thefirst post and found the ground strap problem after I posted the first time so I didn't think too many forumers would return to the origianl post. Call it desperation or neurosis-I have nightmares about my 4L engaging at 70mph.

RE: Isn't this freaky.....
 

An arcing ground strap could cause electrical gremlins. I say arcing because you have a ground strap rubbing on another conductive piece of metal.
The ground strap is just that also, an electrical ground. It has nothing to do with the radio interferrence.

I agree, don't start two threads on the same issue. Some people won't and don't like to jump around from thread to thread.

RE: Isn't this freaky.....
 

I think you just solved it : )

RE: Isn't this freaky.....
 

Apologies to all for the posting debacle and many thnaks to all who chimmed in. Replaced the ground strap - problem NOT solved. Back to square one.

RE: Isn't this freaky.....
 

Is there any way to disconnect the 4x4 from coming on at all - pull a fuse, disconnect a connector, etc, until I can find more time to play with it.

Thank you in advance.

(2002 Montero XLS)

Again many thanks to Off Roader, Sebba, silvercoupe97, Sam0472 and all.

RE: Isn't this freaky.....
 

Called the dealership and talked to one of the techs. He said that there is no way the 4x4 can engage without actually moving the 4x4 lever into the selected range. He said the 4x4 is engaged by linkage, not by some electrical actuator so it is physically impossible for the front wheels to engage without moving the 4x4 lever into the appropriate position.

I explained the gear noise that I am hearing while the 4x4 lights are blinking. He indicated that the freewheeling solenoid may not be venting to atmosphere properly causing the front wheels to be spinning the shaft to the transfer case.

This bad solenoid freewheeling concept may be right on track becausethis gremlinseems to come aliveonlywhen I am decelerating.

Thoughts please?

RE: Isn't this freaky.....
 

solenoid freewheeling: I am not sure what the freewheel solenoid is do you have more information is this some sort of part that works with the vacuum system that enages the front diff.

RE: Isn't this freaky.....
 

Yes, the freewheeling solenoid - as he referred to it - is vacuum operated. He refered to it as a solenoid - which is to my knowledge typically an electrical device. He also indicated that theremay be a leak in the vacuum line or somewhere else. It is, however, a vacuum operated device.

One thing I've noticed. If I shift into 4H when I hear the grear noise, the gear noise goes away, then I shift back to 2H, and life is beautiful for about 10 minutes.

Said they can't really say much morewithout looking at it.

Hope this helps.

RE: Isn't this freaky.....
 

I went under the hood yesterday and found the vents: The solenoid (vacuum switch) is located under the hood on the right side wheel well, there are two switches with I think five vacuume lines on top of the switch there is a little black cap I took it out and cleaned. I also found another vent on a vacuume line about 12 inches away from this one its a soft rubber vent cap on a metal line clean it out they were full of sludge like oil and dust will see if it helps.

RE: Isn't this freaky.....
 

Thank you. When you say the right side of the vehicleassuming you mean thepassenger side of the vehicle. I'm going out to check mine. I'll let you know how it turns out.

RE: Isn't this freaky.....
 

Thats right the passenger side: I cleaned mine on Sunday and its done it once only since then time to trouble shoot some more: Will post my findings I am going to disconnect the Vacuume from the front diff and see if it stops.

RE: Isn't this freaky.....
 

I found the vent caps you described an cleaed them out yesterday. Not really too dirty. Drove the Monty once to thestore, short trip,didn't engage, but haven't really had a chance to drive for morethan 10 minutes - been out on my bike with the nice weather.

This weekend Iplan to drive it. If the problem continues, it's off to the dealershipI go. Keep me posted on your progress Sam0472. If I have to go to the dealership I'll post theirdiagnosis and repair info.

Thanks

RE: Isn't this freaky.....
 

just thought i'ld chime in. i got some stuff wet and my front axle kept engaging randomly going down the road for about a week. while investigatingi realized the vacuum actuator keeps the axle disengaged. without vacuum the axle will engage. rediculous safety feature i assume