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Rebecca 09d40spain

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Discussion starter · #1 ·
Hi everyone just hoping someone could shed some light on my situation

I have an 09 d40 that has no drive turns on fine does have an abs light but that has been on before this issue, I can hear the 4wd switch change from 4 high to 4 low but not when I change it to 2wd clutch feels normal gears feel normal just won't drive anywhere I suspect the transfer case is stuck in neutral is there any way I can test the 4wd switch before splurging on a new one for $160

I also have continuity on all the switches on the tranny

TIA
 
#2 ·
Rebecca 09d40spain said:
Hi everyone just hoping someone could shed some light on my situation

I have an 09 d40 that has no drive turns on fine does have an abs light but that has been on before this issue, I can hear the 4wd switch change from 4 high to 4 low but not when I change it to 2wd clutch feels normal gears feel normal just won't drive anywhere I suspect the transfer case is stuck in neutral is there any way I can test the 4wd switch before splurging on a new one for $160

I also have continuity on all the switches on the tranny

TIA
Click to expand...
Welcome to the forum.

Your diagnosis sounds spot on.

A couple of things to try:

Disconnect a battery terminal and turn the key. Effectively rebooting all the computers. It might work.

Put the main gearbox in neutral, with the engine running switch the tbox to each setting several times. Often the mechanism gets sticky and needs freeing up.

If no joy, then I would remove the actuator mechanism from the side of the transfer box.
You can then check the actuator is doing the right thing, also accessing the spindle that operates the tbox which can be turned to manually change gears.
 
Discussion starter · #3 ·
Thank you for your suggestions

I disconnected the battery, removed the actuator its moving in 4lo and 4hi but not in 2wd so I am thinking there is a miscommunication somewhere or something in the can is stopping it from going into 2wd maybe the abs light has something to do with it?
 
Discussion starter · #6 ·
Do you know of a way to test it?, I'm gunna be pulling the gear box out tomorrow to check the clutch and flywheel, no that's the weird thing it didn't make any noise I just stopped to flick it from 4wd to 2wd and then it had nothing, the gears weren't slipping prior or anything
 
#7 ·
Rebecca 09d40spain said:
Do you know of a way to test it?, I'm gunna be pulling the gear box out tomorrow to check the clutch and flywheel, no that's the weird thing it didn't make any noise I just stopped to flick it from 4wd to 2wd and then it had nothing, the gears weren't slipping prior or anything
Click to expand...
Before you go the effort of pulling the transmission..

Run the engine main gearbox in neutral. Without putting your foot on the clutch try to engage gear. Since the mainshaft should be turning it will be difficult to engage gear and may even cause grating. If it is easy to change gear then i would suspect either the clutch plate or the nasty dual mass flywheel have given up the ghost.
 
Discussion starter · #10 ·
So I'm thinking this abs light might have something to do with it maybe a wheel bearing has let go and is stopping the computer from engaging anything, I have nothing in any gear so was thinking if it's clutch I would still have something in one of them?

Thanks again for all your help so far
 
#12 ·
Ok, if anyone else has this issue, I solved it by removing the 3 switches and manually rocking the shaft that tiggers them back and forth with screw driver. I think I was stuck between high and low range. Probably my own fault since I very rarely use low range
 
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