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Lever operated transfer box on Gen3 with ESC: is it possible?

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19 Dec 2025 07:32 #263138 by Fletch
I'd like to install a lever-type transfer box on my Gen3 with pushbutton controls and ESC.
Has anyone done this yet?
I assume I have to trick the 4WD controller by emulating the enable signal sent by the transfer case sensor that tells whether the 4WD engagement has been completed successfully, right?

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  • Lambert
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19 Dec 2025 13:09 #263139 by Lambert
The stability control is as I understand it run via the abs system so I might have imagined that with manual hubs it should work just with lights on? So then it would just be a matter of having a switch somewhere that gave the expected signal so it swapped between stability and traction control, maybe or not I'm not good with control systems.

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19 Dec 2025 21:20 #263141 by Fletch
I did a little research and found a Suzuki technician training document that explains the entire transfer case operating logic.
The buttons control the actuator, which indicates its position to the 4WD control unit based on the rotation performed. Two switches on the forks, confirming the position, turn on the dashboard lights and activate the pneumatic hub locks. The 4WD control unit, in turn, communicates with the ECU and the ABS/ESC.
If certain conditions are not met, the system does not activate and stores the errors, which can be read by counting the flashes of the light in DTC check mode.
Here is the link to the document (even though it is publicly accessible, it is still confidential material, so moderators are free to remove it if publication is not permitted):  it.scribd.com/document/401798888/SUZUKI-JIMNY-4WD-SYSTEM

Now my question is: using a lever-type transfer case, how do I make the 4WD control unit understand that the actuator position is valid if the actuator is no longer present?
I could remove the actuator from the transfer case and place it in a protected location, keeping it connected, and manipulate the ground signals that the transfer case switches send to the 4WD control module.
Or, premising that I'm absolutely no computer expert, I was thinking of an emulator/controller based on Arduino, that could send the signals and values ​​needed to operate the 4WD system without the necessary components being present. Could it be possible?

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