Suzuki Jimny Type 7, Transfer Case Malfunction

Suzuki Jimny, one of the best 4x4 vehicle around the world. It was compact and short wheel base, make it easy to drive on off road or hill. The 4x4 mode in the Suzuki Jimny was activated by pushing the swith in the center of the dashboard. There are 3 switch, 2H, 4H and 4HL.

This is the function of those switch :

• "2H switch" is pressed to shift 4x4 high range or low range mode to 4x2 mode.
• "4H switch" is pressed to shift from 4x2 mode or 4x4 low range to 4x4 high range.  
• "4HL switch" is pressed to shift from 4x2 mode or 4x4 high range to 4x4 low range.

To shift from any mode to 4x4 low range, vehicle should stop and press cluth pedal if it was Manual Transmission or in Neutral position for Automatic Transmission. The logic command to activating 4x4 from 4x2  mode is :

1. Press "4H switch", vehicle speed is less than 100 km/h, front wheel on straight-ahead position. This "4H switch" sends signal to Transfer Control Module to activate Transfer Shift Actuator on Transfer Case, during this operation, indicator 4x4 is blinking.
2. If Motor limit switch in the Transfer Shift Actuator reach its position then 4WD switch on transfer case turn-on and sends signal to Transfer Control Module that the transfer case is engaged on 4x4 mode. The Transfer Control Module also activate air locking hub on front both wheel to engaged front drive shaft to front wheel hubs. This process then finished.

One of the problem that I have encountered is when "4H switch" is pressed, the 4x4 indicator only blinking, Transfer shift actuator did not rotate. After checking the input and output, found there are open circuit on 4WD switch and 4WD Low switch. Because indicator was blinking, this means Transfer Control Module receives input and sends signal to the Transfer shift actuator. when the indicator switch off, it means Transfer Control Module did not receives signal from 4WD switch and 4WD Low switch.