I've yet to find an exact help page or manual area for troubleshooting the American or equivalent version of the FULL SIZE 1999 - 2006 generation 3 Montero / Pajero. There's one for the UK I found written in 2006 and all the photos look different...it's for a right-hand drive model of unknown motor/body type.

I have flashing lights and failure of the front axle/hubs to engage or disengage when I change the electronic shift selector. I can sometimes get it to cooperate with much jiggling of selector lever, moving around, juicing it, or turning the ignition on and off, but not always. And it seems random what makes it work again.

The lights only flash when I try to engage or disengage the 4wd. When its operating correctly in 2wd I don't have blinking 4wd or Center Differential lights.

Any references to good trouble shooting procedures or help would be appreciated.

I'm also looking for any information about making the front hubs manual locking or otherwise upgrading so the system is less electronic / switch / vacuum dependent. Anyone tried changing your Montero to a better engagement system and/or manual hubs?

I put 5 oz of 91% iso rubbing alcohol in an old contact cleaning bottle (after I rinsed it with vinegar) and sprayed about 1/2 ounce at a time all over the 4wd shift selector while working it up, down, pushing it down, etc. Did the gear selector also.

My Limited model has the plastic sliding cover that moves up and down as the lever is moved...so the alcohol flows into/around it and down the shift lever shaft. It's not like the XLS that has a protective vinyl cape or bag over it.

Last fall 2015 I spilt about 6oz of coffee with honey and creamer on it and was traveling so had no way to properly clean up...I think that was making for sticky electrical connections.

So do this first before visually checking switches, lines, wires and cleaning them! Easy fix.

I have two 2001 XLS models and both of them apparently have a burned out center differential lock (CD) light. The 4wd drive selections work (2H-4H-4L) and all the wheel lites too but the CD box will never light up on 4wd Low.

It feels to be working but is there a way to confirm the Low lock is working?

See the FAQ thread above. I can tell you haven't read it thoroughly. This is addressed there. BTW, I'm not trying to be a jerk here. Just want you to check it out since we all spent a lot of time creating it and it really can be an excellent resource for you.



Again, please read the FAQ threads above as although I can't be 100% certain this may be addressed there as well in the How To Fix & Maintain section.

It could just be the lights are failing and not actually the transfer case. I'm not 100% sure on this but earlier Monteros were all Mechanically actuated transfer cases and the indicator was lit based on the transfer case levers position via a solenoid. The most common problem was a failing solenoid.

Alternatively if the car is physically not disengaging the front drive train, then it could also be addressed by following the noted procedure in the FAQ post above.

a good place to start is the freewheel vacuum solenoids. Right under the airbix behind the right front headlight.
Leaving it in 4h will keep it happy when these fail.

The ones on Amazon listed as replacements won't work as well.