I have a 88 suzuki samurai. I moved the lever to four wheel drive made sure the manual lockouts were locked and the truck would not engage to 4WD. There isnt a noise no clunking or anything. Just wont engage. I think it is time for a new transfer case. or something is stuck. Can someone hel me out?
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Using the shorter gear leaver in the samurai, the gear choices are arranged in a simple U fashion. They are arranged in sequence. At left top, bottom, right middle and right top you have 2 high(2H), 4 hight (4H), neutral(N) and 4 low (4L). 2H- Engages rear wheel drive only. 4H- Engages all wheels in 4X4 mode. N- Disengages all wheels (if you gonna tow your vehicle) 4L- Engages all wheels in 4X4 mode with 50% more torque but you cut your top speed by an equal amount. If you have the OEM gear knob the diagram of the layout of the transfer box should be imprinted. 2 high should be used on dry and mildly wet paved roads. Using 4L or 4H in these conditions may result in damage to your transfer box. You may use 4L or 4H in any other road conditions.
the samurai doesn't have 2L it has 2H. there are 4 modes on the transfercase. 2H, 4H, N and 4L. 2H engages the rear wheels only while 4H and 4L engages all 4 wheels. N disengages all 4 wheels, useful for flat towing.
There are three driving modes: 2H, 4H and 4L, which stands for 4x2 High, 4x4 High and 4x4 Low. There is a modification that can be made on the transfer case to add a 2L (4x2 Low) mode, but that's not original. In order to use any of the 4x4 modes you will also have to step out of the car and turn the free wheeling hubs to the "lock" or "4x4" position.
I'm assuming you know how the shift works.......sometimes it is a little difficult to position the lever correctly. Due to a possible problem with the plastic "cup" that supports the shift lever, you will need to remove the shift lever from the transfer case, and Use a big screw driver to move the mechanism to the neutral position. Many Samurai suppliers offer the kit to fix the shift
Will the leaver not move? Try reversing a little, the forward. This might let it slip in place. Sometimes you get transmission wind up, causing the 4wd drive not to enguage. If it won't come back out try the forward and reverse thing again. I don't understand the light being on and your still not getting 4WD!
If it has been lifted the Pitman arm needs to be adjusted to recenter the steering.
With the engine off, the trans in gear and the transfer case in 4 Hi or Low you should not be able to rotate the front drive shaft. If this is the case it sounds like a hub problem. Make sure the hubs are engaged. If so the hubs could be rusted and need cleaning to work freely.
First thing just try to push or pull the 4x4 lever if you get it to move and it feels like it went into some gear try to drive the truck.If this works look on the shifter for the 4x4 and put it in 2 wheel drive (H2 is two wheel drive,H4 is 4x4 high,and L4 is 4x4 low range).Make sure you have the clutch depresed when you try to move the 4x4 lever.If you try this stuff with no fix try and look for clutch adjustment on the transmision you may need to adjust it or your clutch is bad.
As far as I know the procedure should go something like this...
Stop the vehicle, engage the parking brake and if applicable, get out and turn the hubs on the front wheels from Free, to Lock.(You may not have these on a Suzuki, they may be auto-lockers)
Get back in the vehicle and put the transmission shift selector into Neutral.
If you have a manual transfer case, move the selector-shaft to 4x4-High, or 4x4-Low -- whichever is desired. Now, putting the vehicle in gear with the transfer case is sometimes somewhat difficult. As long as the vehicle's transmission is in neutral, don't worry, the gears inside the transfer case are big and beefy -- Don't be afraid to be rough -- Again as long as the transmission is in neutral. You may also have to disengage the parking brake and slightly let the vehicle roll forward or back with your foot-brake to get the Transfer case to lock into place.
Once 4x4 of the selected High, Or Low range is selected, usually indicated by the vehicle jerking slightly with a slightly loud clank/thud. Move the Transmission selector out of neutral into your desired gear (Drive if Automatic, if Manual, whichever gear you pull out from). and voila! You should now be in 4-Wheel-Drive.
To disengage 4-Wheel-Drive. Just reverse the steps.