I am waiting for my engine to get back from the rebuilders

In the meantime I'm tackling electrics and at the moment I want to get the 4x4 lights in the dash to work.

The rear wheels light ( green ) is not working but I traced that to a blown bulb.

The vacuum operated front diff system works

The only thing now is to get all 4 green lights to light up when I select either 4H, 4HLc, or 4LLc

I have followed the manual I got from SimonB ( thanks again )

and here are my results






Unfortunately there is no instruction or reference of how to remedy this or where it actually goes to or comes from. Anybody with some experience on this ( I believe this is a pretty common thing ) <img src="/forums/images/graemlins/confused.gif" alt="" />

There are switches all over the T-case to indicate where it's positioned. Someone said 11 switches in total to me once with the backup light switch. They all seem to be alike but have either N/O or N/C operation. I'm guessing your 4lo switch is out and not feeding voltage to the control unit.

I have removed them all and tested their operation. They all work as intended ( they ground the circuit - not relay voltage )

Maybe they don't work on the transfer case itself.

the bottom bulb is blown ( 2WD )

but the top one is not blown as it flickers sometimes when shifting between 4HLc and 4LLc

Originally Posted by rockett
Someone posted somewhere that the switches in the transfer and gearbox and diffs can become a bit worn down after a while so the correct signal is not always sent so that the correct lights are lit.
The fix was thinner washers. I have no idea where these switches are located. If that can be posted, then that can be traced and checked as well.


This ( thinner washers ) sounds like a good test because it flickers sometimes when switching between 4HLc and 4LLc

I have removed them all and tested their operation. They all work as intended ( they ground the circuit - not relay voltage )



Maybe they don't work on the transfer case itself. I need to try that thinner washers thing.

Anybody with a picture from the top of the transfer case with the switches labeled?

These are my findings

NOTE :
I have not commented on the rear wheel green lights as
1. My bulb is blown
2. They should be permanently on with the ignition so they never change





First picture courtesy of 4ePajero

Hence my trouble is obviously with number 5

Success. <img src="/forums/images/graemlins/smile.gif" alt="" />

My lights are working the way they should except for the rear wheels (of which I presume the bulb is blown)



The rear wheels bulb I'll check out this week and replace or re-wire as necessary.

The dash is back in but I realised that only one speaker is wired. <img src="/forums/images/graemlins/evil.gif" alt="" /> ( That is gonna be another headache chasing cables )

Updates

I fixed the dash lights and made a DIY about it here
- http://www.4x4wire.com/forums/showf...&an=0&page=1#Post1166466





I have also had word that the engine is stripped and almost clean.

I will go and have a look tomorrow afternoon and take my camera with.

Good job Marius. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Keep up the good work, your Monty will reward you.

Good job, I miss my Gen 2..

stripped

It is not as bad I initially feared but it is clear that the previous owner did no maintenance for over 50k.

The bores are slightly scored but if you look carefully you can still see the original honing marks after 250k <img src="/forums/images/graemlins/kewl.gif" alt="" />

The crank is slightly scored - due to lack of decent oil and VERY old oil - the workshop reckons it is 60k overdue for a change <img src="/forums/images/graemlins/scared.gif" alt="" />

Good news is that a bore ( with new pistons ) won't be necessary - just a good re-hone

I'll let the pictures speak further