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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.
'The actuator' - It has been described to me (I can no longer get out and under cars; age knees and hips) there is a mechanism that is rather like a windscreen wiper motor that changes something inside the transfer box. A second mechanic (one man band, works on everything and local) is also perplexed why the manual hubs do not engage. The front prop shaft is turning, so the front axle must be turning, so why won't the manual hubs as now fitted engage?! With the vacuum pipe from the manifold clamped shut, there should be no need for any vacuum system to have an effect on the whole - unless I am very much mistaken. There's something very simple amiss and I'm missing it - or there's something complicated and I am not understanding it. Super inconvenient at the moment with the amount of snow in rural Shropshire.
Apologies for delay in replying, we had a 48hr power cut. Back on late last night.
For 4wd to work you need both the transfer case to engage drive to the front axle (using the windscreen wiper motor) and the hubs to lock. The system engages at the transfer case first to get everything sinning up to speed and then switches the vacuum hubs to engage.
You have replaced the vacuum hubs with manual ones and (hopefully) bridged the white connector under the battery to trick the system into thinking that is all working fine.
If the manual hubs are in the locked position and the white connector is bridged that's as much as you need to do with regards to vacuum, hubs etc.
Everything else comes down to the transfer case doing its job properly, which I strongly suspect it hasn't been doing from the start.
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