Replacing the 4WD light switch

[hilux_1990]

Hi guys,

I've got a 1991 dual range 4wd wagon. The 'LO' range light works okay, but the 4WD light with the 4 wheels doesn't work.

I tested the wiring and switch and found the switch is buggered.

 

The switch is located on the end of the transfer case, right above where the tailshaft comes out of the tranny. I don't think I can get a tool in there to remove it (no body lift ) so what do people recommend I pull off without just yanking the whole transmission?

 

I was thinking of removing the crossbrace below the tailshaft, the tailshaft, draining the fluid and replacing the switch and perhaps the rear seal.

 

Anything else I should do while I am there? and would anyone recommend a new switch over one from a junkyard?

 

interesting fact: when I was looking to buy an L-series I discovered that ~every~ vehicle I looked at either had a faulty 4WD light or a faulty LO-range light. Every vehicle.

[subiemech85]

see if you can have access when you remove the gear shift boot?

my lo and or park brake used to be on whenever it wanted to !

[hilux_1990]

On the L-series the transmission is located further forward than the hole for the gear sticks.

 

I removed the two-piece tailshaft in order to gain access to remove the 4wd-high-range switch. I made a special socket to fit the switch by taking an appropriate 'cheapo' socket and cutting a slot in the side with an angle grinder. This allows for the wires coming out of the switch.

 

I picked up a working switch from the wreckers but I was able to fix the existing switch by squirting lots of brake cleaner inside the switch until all the dirty oil had been flushed out. A test with a multimeter showed the switch was now working.

 

You can probably get away without draining the tranny fluid by jacking up the rear of the vehicle. I replaced the transmission output seal as well.