Manual or fixed front wheel hub heads

Suzuki Jimny 4WD controller module (<'05)

This quick guide is applicable to all Jimnys with a manual 4WD selection mechanism (lever, not buttons).

One of the modifications often done to Jimny is replacing automatic (vacuum operated) hubs with manual ones. The modification itself is straightforward, but one of the drawbacks is that you are left with a blinking 4WD light on your dashboard. Moreover if you did not remove the vacuum system (solenoids, valves, etc.) it will still function, which is pointless.

A simple solution to both issues is to get rid of the 4WD controller module and connect the 4WD light directly to a switch in the transmission box.

Instructions

In order to do that you need to locate the module. It is placed just above the speaker on the driver's side:

4WD module location (in LHD vehicle)

The coupler is easily removed by hand, and the module itself is held in place by a single M10 nut (located on top of the module).

Unplugging the coupler completely disables the vacuum system, as well as the 4WD light. If you now start the engine and move the 4WD lever to 4H or 4L position you will have no indication of that on your dashboard (of course the 4WD drive will engage as usual provided that you switch the hubs to 4x4 position).

To re-enable the 4WD light you need to connect the blue/black cable (it comes from the switch on the transmission box) in the coupler with the blue one (it goes to 4WD light and the ABS module if equipped). Just connect the aforementioned cables with a piece of wire and do not forget to secure and insulate the connection.

A coupler setup with 4WD light re-enabled after 4WD module removal

Disclaimer

• This guide is provided AS IS. You modify your car at your own risk. I don't know if it is legal in your country/area/religion/whatever.
• I have tested it on a non-ABS vehicle and had no errors or malfunctions originating from this modification.
• I would highly advise however testing an ABS-equipped vehicle functioning in a secure environment.
• THEORETICALLY, if you have an ABS version and you unplug the module and connect blue/black and blue cables the ABS controller should receive exactly the same reading as before (it's the same blue cable, it gets the same nominal 13V current). I just have no way to test it.