FJ62, 1988, Sahara, 4wd Light always on

Submitted: Friday, May 12, 2006 at 16:57
ThreadID: 33834 Views:2940 Replies:8 FollowUps:4
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Hey Guys,

2nd post for me on here, am gradually do up my fj62 and keep finding problems.. 4wd was off when i purchased it, the first time i put it into H4 it would turn off... after driving the car for a whole and putting it in an out of L4 back to H4 for several different terrains when i then went back to H2 to highway use the light went off. It worked properly for about 3 weeks after the first fault. However now it is always on again. I cannot get it off no matter what i do.....

Any ideas?

I have tried reversing, no great distances tho, just 5 meters or so...

any ideas? please help, am i out of 4x4? should i leave my front hubs locked?
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Reply By: Mike Harding - Friday, May 12, 2006 at 18:03

Friday, May 12, 2006 at 18:03
Sounds like it may simply be a stuck switch? I would assume that somewhere in the drivetrain is a microswitch which decides if the vehicle is in 4WD or not and it may have failed or dirt has gotten into it?

Unlock the hubs. That way if it really is in 4WD you won't cause transmission wind-up on sealed roads.

Mike Harding
AnswerID: 172338

Reply By: cipher - Friday, May 12, 2006 at 18:15

Friday, May 12, 2006 at 18:15
Thanks heaps for your help mate, does anyone know the mechanics or where this switch may be?

I can hear the relay opening and closing, then i got from N to L4, however from N to H2 i dont hear anything.... i think that may be the key to it all...

AnswerID: 172342

Reply By: HJ60-2H - Friday, May 12, 2006 at 18:31

Friday, May 12, 2006 at 18:31
On your 60 series do you engage 4WD with a lever on the floor or a switch on the dash?
AnswerID: 172345

Reply By: cipher - Friday, May 12, 2006 at 18:44

Friday, May 12, 2006 at 18:44
i engage H4 by the push of a button

I engage L4 by opperating the lever on the floor.

I can hear the relay open/close when i push the H4 button...

AnswerID: 172349

Reply By: HJ60-2H - Friday, May 12, 2006 at 19:14

Friday, May 12, 2006 at 19:14
The 4WD engages by a vacum relay/actuator opeated by the dash switch. Drive forward/accelerate gently with wheels straight ahead and then suddenly take you foot off the accelerator. Might take a few goes.

If this doesn't turn the light out then either the light switch on the transfer case is suck or the 4WD vacum actuator is stuck. You can manually move it out of 4WD by gently applying a hammer to the 4WD selector.

The Gregories Manual talks about this 4WD actuator mechanism. Is it a 4 speed or 5 speed gear box?
AnswerID: 172354

Reply By: cipher - Friday, May 12, 2006 at 20:22

Friday, May 12, 2006 at 20:22
Hi, thanks very much for your help i will have to give the accelerating and then remove the accelerator quickly...

The box is a Auto 4 speed..

i know auto... yuck...
AnswerID: 172364

Follow Up By: cipher - Friday, May 12, 2006 at 22:26

Friday, May 12, 2006 at 22:26
why would that matter?
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FollowupID: 428001

Follow Up By: HJ60-2H - Saturday, May 13, 2006 at 23:10

Saturday, May 13, 2006 at 23:10
Arrangement of the vacum mechanism differs in location between the 4 & 5 speed boxes.
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FollowupID: 428235

Reply By: DamoHJ61 - Saturday, May 13, 2006 at 23:00

Saturday, May 13, 2006 at 23:00
Check all the good ideas offered so far hopefully you will find a solution that works but also check the vacuum lines and switch, if the problem is not mechanical you may have perished hoses or a dud switch.
AnswerID: 172587

Follow Up By: HJ60-2H - Saturday, May 13, 2006 at 23:09

Saturday, May 13, 2006 at 23:09
If the vacum fails then you are in 2WD. It is the vacum that puts and holds it in 4WD
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FollowupID: 428234

Reply By: cipher - Sunday, May 14, 2006 at 12:35

Sunday, May 14, 2006 at 12:35
hi guys,

tried the accelerate then take off, didnt work, did about 20 times, lol

By gentle hitting the 'actuator' with a hammer by that do you mean the L4/H2 selector? or underneath the car or a relay that the H4 button goes too???

Sorry guys, am new to 4wd's :-S

cheers
AnswerID: 172620

Follow Up By: HJ60-2H - Sunday, May 14, 2006 at 19:14

Sunday, May 14, 2006 at 19:14
Underneath the car. You will likely need to remove the bash plate. Look for the vacum actuator. Gregories manual helps you in this respect.
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FollowupID: 428285

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