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Short history; Previously had a Gen3 05 plate, manual engagement of 2 x 4wd. No issues (except rust).
Replaced with Gen3 08 plate, push button 2 x 4 drive. Worked OK, then stuck in 4wd low. Followed a tip and reversed a few times - all good.
Months went by, selected 4wd low, stuck again. Would not come out.
Mechanic fettles transfer box, gets it back into 2wd, but issues. Cannot select 4wd.
Vacuum pipes checked - all sound. One way valve checked - sound. Circular solenoid(?) replaced with new. Blue twin solenoids cleaned foam filters replaced (just the filters). No joy. Electronic control unit beneath dash replaced. No joy. Both transfer box sensors (spring switch with lead and plug x 2) replaced with new. No joy. Another mechanic with the aid of a Suzuki auto electrical specialist checks the system out: vacuum all good, possibly 'in oil' sensor within the transfer box duff. Expensive - opt for fitting manual hubs from Lamberts.
Fitted, operated, but not driving the wheels! Recent snow and ice - rear wheels spinning only, despite manual hubs engaged.
Do I now look at replacing the transfer box?
Does this sound familiar to anyone? Love to hear comments.
When they worked - it was great. The old vacuum actuated hubs were clear and free, not seized. The front prop shaft turns in 'drive', what am I missing? A couple of hundred quid gets me a used unit for an 08. I'm tempted! I'd love to have it working from inside the car.
Last edit: 08 Jan 2026 14:09 by Degsy. Reason: typo
I'm sorry you've gone to all that trouble with the vacuum system and hubs but this was clearly a transfer case issue from the start. I'd take the actuator off, inspect and clean.
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