Diagnosing and proving how Pajero/Montero 4WD actuator solenoids work

** Disclaimer: I had a bad cold when making this video and man, did I get some stuff backwards. Fundamentally what I say in the video about how the system works is correct, but when I talk about when solenoids are on or off based on a voltage reading, or the front diff actuator rod is in or out, I may have it backwards. Sorry folks. **
Following on from diagnosing that my 4WD "Super Select" aka "Active Trac" 4WD engagement solenoids are the root cause of 4WD engagement issues on the NL Pajero, I decided to dig a little deeper and see exactly how these buggers work.
It's actually a really reliable system (aside from those dang solenoids LOL). The control box does very little other than tell you whether it thinks 4WD is working properly, but you could literally remove the control box completely and, assuming the solenoids and vacuum lines are OK, have a fully functioning 2WD/4WD selection system.

[@scottfellers1943]

I love how in depth you went on this. Not only showing how to fix the problem but giving a really nice demonstration on how the 4wd system works. Some of us really like to know the "why" behind what we are doing, not just blindly replacing parts. Really great work!

[@eugeneclarke672]

That's a brilliant explanation of the 4x4 system. Thanks for posting

[@EVERYTHINGOVERLANDANDUNDER]

Thanks for the video mate.... Helped me on a 2018 Triton to get my head around how Mitsubishi did this... 2018 was obviously more involved, but basic thought process was the same

[@finnmckechnie3901]

Thanks for this video mate. Super helpful and great in depth explanation

[@gjcarr2991]

The old flashing issue...yeah sorry fixed my issue as well...as long as I can get it into 4wd when I go to Fraser I'm happy...any way great vid mate, well detailed and grey explanation l.....also yeah CPAP machine changed my life too.....keeps those vids coming

[@woden20]

THE Best video on youtube showing how it works. 👍

[@bigfich123]

Great video. I replaced my solenoid and it still doesn’t want to engage 4x4. If I unplug the solenoids I can trick it into engaging 4x4 which is odd and vice versa. Have left it in 2H for about a year now as gave up on it. But this video has given me insp to try fix it again

[@DanielNicholson-sb9tc]

Bro I'm 40 and had the same yarn with the sleep apnea.. Anyway long story short I started doing 30 mins cardio and dropped to low carb beers... didn't have to give up the piss but it cured my sleep apnea 😅😅

[@firecrackerg60]

Good video... hope this is my issue. At least i understand it a whole lot more now. Appreciate your effort in making this clear and informative 👌

[@KaldekBoch]

Thanks. I could do better but I often lack the time.

[@Scottadamsfan3481]

Yes I agree about the breathing issue, oh he also solved a car problem as well

[@johnrickard4326]

Great video bro. Sorry to hear about sleep apnoea, hope you get on top of it. My 2005 delica auto has locked up all wheels, had to skull drag it to mechanic only for them to say its not the diffs or transfer case and I need to buy another auto. No mention of solenoids until I asked them were they checked. Then of course they said yes. I am very suss if they were checked. It wasn't on the bill either. Now they want it gone and I have to pay for another tow to get car home in same condition. The guys at delica garage said it could be the solenoids but I am in Cairns with no one here I trust. Only been here a short while. Anyone else had this experience? Any help would be appreciated. Cheers.

[@Mrveescuba]

Hi there i have shogun/montero/pajero 2004 did..and it start flashing orange when i turn off the ignition ans start the car again many times went off and everything works as it should!!couple of days now and the flashing ligth came plus another 2 ligths top left i think is antispin or something..any idea if its about solenoids? or trasnfer case swich??thanx for the vid anyway

[@edwardmorrison2461]

Same problem on MK. Disconnect the vacuum hose from the solenoid and 4x4 engages.

[@user-vp1ti9pz9g]

Hey mate, where did you get the electric schematics? Great video!

[@alansookraj3501]

Great video

[@bigfich123]

So my issue is that 2H works, changing into 4H the solenoids don’t turn off and it doesn’t engage the front diff and continues flashing. I can manual engage 4H but unplugging the solenoids. So would this be the 2-4 switch or the free wheel switch

[@ietifindingsolution]

I have same issues in my 2000 Mitsubishi pajero it siting for 1 years now I plan to fix it soon thanks for video 📹.

[@KaldekBoch]

Cheers mate. The switches in the transfer case and on the front diff may also need cleaning. My NH Pajero which I'm selling to a mate needs the switches cleaned up. Contact cleaner is your friend there.

[@cyclopsfpv247]

Thanks for the vid! Been looking for answers to this flashy light problem for a while now. I pulled my solinoids out and tested them on 12v. They seemed OK, but still having issues with lights flashing when putting it into 4H. It does engage though, so must be the detection switch that is dodgy.

[@KaldekBoch]

Yeah this is just a reminder that what I really need to create is a video which has a flowchart that goes through how to diagnose the cause of flashing lights, as there's more than one reason why they flash.

[@KaldekBoch]

Also I just put a set of solenoids in my other Pajero (the NH) and it also still has some issues, so it also obviously has some issues with the detection switches. I'll start with the switch on the front diff as that is the logical next place to look,

[@traveldiaries6078]

Hey mate I got same 6g72 engine 92 paj hard to start on the cold intake any idea changed lot of things spark plugs ,0z sensor ,throttle body ,fuel pump ect

[@BackyardRussia]

Whats the part number on that solenoid?

[@pierogillio]

I have no voltaje on the selenoids conector, any idea if there is some fuse??? Voltaje show 0,01 but it has continuity

[@robinodell9453]

I think the diode is fitted to help with the power dissipation when the solenoid coils are de-energised. Common practice in industry.

[@KaldekBoch]

Thanks mate, I don't think I would have picked up on that.

[@xrotor7813]

Great in depth video - I have a 2002 Montero in Canada and have an intermittent issue with the flashing center diff light too. However I just have the flashing center diff light after 20-30 km of relatively high speed driving. If I am driving around locally (slower in traffic) then I never get the error. I am guessing that my leak is small and only ever produces the error when engine vac drops under load for an extended time when the vac tank is depleted as well. Does this fit with anyone else's experience?

[@KaldekBoch]

Your flashing center diff light - does it come on when you're in 2WD mode or 4WD mode (only) or regardless of that setting? Most likely your issue is a sticking centre diff lock switch on the transfer case. I need to make a better video on the overall system but the majority of the Active Trac/Super Select system is totally mechanical based on the transfer case lever and its associated forks that engage gears in the box itself. The rest is all just microswitches which dictate what lights flash on the dash.

[@xrotor7813]

@@KaldekBoch the flashing center light only shows when driving in 2WD just like in the video. I had a spare freewheel control in the tool box so I just swapped it to check.

[@KaldekBoch]

@@xrotor7813 In your case I would remove and clean/test all of the microswitches that connect into the transfer case. I suspect that will be the root of your particular issues.

[@mikebishop532]

good shout out on the apnoea. the sleep study changed my life too

[@willy37392]

Ser, Can i have a copy of this electrical diagram montero V78, my car in trouble with this motor actuator in transfer case. Not respon if i switch 4wd handle. Thank you

[@riverinabarter-lm4si]

Oh wow that 😢 never head of awake apnea it sounds like my son x I'll get him checked out

[@Siegrfield85]

My pajero blinking the front wheels when 4x2 is activated ... can you help me ? Plz

[@thomasmacokatic6219]

got the same problem. 93 td im gonna try swap that part and spray switches like he suggested in a earlier comment response. lemme know if u fix before me :)

[@thomasmacokatic6219]

hey man i literally pulled the vacuum switch plugs out like he showed in this video and cleaned with contact spray and the lights stopped flashing immediately after :) hopefully stays good, just thought id let ya know

[@Scottadamsfan3481]

Airbox clips broke is probably why they did those screws

[@Scottadamsfan3481]

I have same breathing issue

[@drtone]

so by swapping vacuum lines, u could get 2WD lo ( lever positions changed :: 2h=4h, 4h=2h, 4hlc= 2h, 4llc= 2l)

[@KaldekBoch]

Do you mean changing the lines so they're in the wrong place? I suppose you could do something wacky like that, but why?

[@drtone]

@@KaldekBoch Yes, purposely swapping them in wrong place. Reason why is I have Pajero EVO and can do over 110 kph/70mph well below redline in 5th gear(auto) in 4llc for aggressive rally cross and off roading. The torque multiplication makes truck feel like 400hp(?) I want to be able to select low gear in transfer case, but be in RWD only, and AWD( ie open center diff 4lo). Ideally, it would like to retain traditional 4llc for self rescue, I think it should work, i suppose additional vacuum solenoid plumbed in could make ultimate systems. maybe paddle shift actuation

[@drtone]

Does 4llc happen in the transfer case,,,,,and the front vacuum actuated axle connector not involved?

[@KaldekBoch]

@@drtone Ah I don't think that would do much. The Low and High is a mechanical setting via the 4WD lever in the cab. The solenoids don't do anything other than control whether the front diff is engaged or not.

[@KaldekBoch]

@@drtone Correct. The vacuum axle connector ONLY engages whether the front axle is engaged. The transfer case controls the Low/High ratio mechanically.

[@jojodelima1953]

at least understand it better how that solenoid works, its kind of technical checking if its properly working or not