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ARE THE HUBS LOCKED IN FIRST? FOR YOU HAVE TO LOCK AND UNLOCK THOSE HUBS FROM THE OUTSIDE.. EACH TIME YOU GO INTO 4X4 AND WHEN YOU GO OUT OF 4X4 TO 2 WHEEL..DRIVE. OR YOU DON'T HAVE A FRONT DRIVE SHAFT GOING TO THE FRONT AXLE?? OR ITS BROKEN OR THE TRANSFER CASE IS BAD??
I believe that Mitsubishi has one of the best and easiest 4X4 selector systems on the Pajero/ Montero. Just below the gear shifter lever is the 4X4 mode selector. A lever like the gear shifter that works in a up, down movement. On your dash board you will notice a sort of axle, chassis diagram in green light. In normal 2WD or 2H mode the lever is set all the way back and on the dash only the rear wheels a lite up in green light on the axle, chassis diagram. This is for normal driving on the highway and smooth roads of dry dirt roads. Pushing the lever up wards while moving at crawling speed will engage the light 4X4 mode which is 4H for when the driving gets a little slippery. All 4 wheels on the axle/ chassis diagram will be lite green. Shifting the lever from the 4H position to the left and upwards will engage the 4HLc mode for 4X4 on sand and deep snow. This will also engage the central diff lock which will show on the axle/ chassis diagram on the dash board with the center box also lite up. Further up from the 4HLc mode and while pushing down on the 4X4 lever push it to the top most position, but only do this when at a stand still with your foot on the brake pedal. This will engage the 4LLc mode with 4X4 and central diff lock on for when driving gets sweaty on thick mud up and incline. To disengage this mode stop, foot on break put it in P and then pull down the lever to one of the lower settings.
You can shift between 2Hi and 4Hi when the truck is moving. Just let off the gas and shift it. But in order to shift to Neutral or 4Lo you need to stop the truck and shift the transmission into neutral then shift the transfer case.
Lift and support the front of the truck so the front wheels are off the ground ( take safety precautions, chock wheels, jack stands, etc ). Key on, engage 4x4 and try to turn the front drive shaft. If it turns it is a problem with the transfer case. If it doesn't it is a front axle engagement problem. I would guess a problem with the vacuum disconnect motor on the front axle ( or vacuum lines from teh solenoids or the solenoids themselves ), but best to verify the test above to know which way to go. Post back a comment after the test.
This is for 4x4 shifter on the floor.
In the front of the truck on the axle there's a plastic cover with 2 10mm bolts remove it and spray down the shifting actuator it operates on vacuum. You might have to pull it in four wheel and check to see if the vacuum pod is engaging the shift lever on the axle. Then again you might have to replace it very easy to do. But I would spray it down with some WD-40 it should work.
shift into 4wd and move truck a couple of feet.
if light is still off, park truck block the wheels set the park brake jack right front wheel and try to hand spin the wheel if wheel doesn't turn 4x4 is functioning properly but there is a wiring problem use an ohmmeter to check the 4x4 switch wiring fuse and bulb
if wheel turns freely the front axle or transfer case is not engaged
attempt to hand spin the front driveshft if the driveshaft will spin the transfer case is not engaged check the transfer case shift linkage, problem is in linkage or transfer case internals
if the driveshaft will not spin the transfer case is engaged properly
with trnsmission in neutral or park start engine measure vacuum on the two vac lines at front axle shift motor . one line should have approx 20" vacuum. other line should have none
if no vacuum measured look for vac leak or bad vac switch
if both lines have vac look for a bad vac swithc or ruptured cad actuator diaphragm
if one line has 20" +- VAC
move transfer case lever to 2wd measure vac again lines should have swapped vac signals
if no vac switch bad or 4wd shift likage needs adjusting
if yes vac motor bad or stuck or shift fork stuck
remove vac shift motor from the axle attach vac lines to shift motor engage disengage 4wd
does shift motor plunger move at least 1/2 inch
no shift motor bad
yes check axle shift fork and vac motor for binging
if you look there is probably only one axle shaft turning also that shaft should not turn unless the wheels are there is probably something wrong with that hub not a big problem to tear down and check you can also get replacement hubs that are manual locking.