CDL Problems

[TX_TLC]

Dear Forum gods,

I have a new to me stock 1994 TLC FZJ80 with no FF/RR lockers...I have searched and read a lot of great information but I have yet to find my exact situation so I would like some help...more so than sending me to the search...

I shift into N....shift 4wheel into L...I get NO CDL light (flashing or non-flashing), NO ABS light, and I hear no "click" or "clunk" or any other sound coming from the DS Kick Panel.

It does shift into the lower gearing and everything but I know it is not locking...just one slight turn on a loose dirt surface told me that.

What I have done:

I have crawled underneath and burned myself on the CC...OUCH! Once I got to the Center Diff, I noted no plugs undone or loose. I have read the write up on Slee about shorting the Center Diff Lock transfer indicator switch, but I am not sure which one it is and don't want to screw anything up. Will this even help if I am not hearing any noise from the kick panel?

The PO (original owner) said he only used it for HWY driving...and never off roading, several other signs have pointed to this type of use. I just hope the CDL is not completely froze open.

Any and all help is much appreciated!

Thanks for all the great information so far...I am looking forward to many many many great years with my Cruiser....

David Connor
Abilene, Texas

 

[semlin]

there are several historic threads on CDL problems that sound a lot like yours. Just search "CDL" and be patient. A common suggestion is to by the optional CDL swithc, install it, and see if it works. This will troubleshoot you some distance.

OK, I needed to try out the new search function anyway, so here are some links I found with your exact situation (search works almost too well now -- good job Woody):


https://forum.ih8mud.com/showthread.php?t=10851&highlight=CDL

https://forum.ih8mud.com/showthread.php?t=10367&highlight=CDL

https://forum.ih8mud.com/showthread.php?t=9586&highlight=CDL

 

[Biff]

TX, I have the same problem. The previous owner drove mostly highway miles in the 10 years he owned it.

 

[PHAEDRUS]

I have spent more time than I care to think about on this one,
basically the system is three parts.
well if you have the switch it adds a fourth part,
first is the shifter (or switch if installed) this will send a signal to the relay in the ds kick panel. this then fires current to the cdl motor if working properly.
the motor is a simple motro with two way wiring ie if you have +=1 and -=2 then it engages forward if +=2 and -=1 then it will disengage.
Now my truck is a 92 so a little different but hte wiring to the motor is identical.
once the motor engages it pushes a spring wich will lock the viscous coupler (only on 93 up trucks) forward and then the sensor will show it is engaged and send the signal to the controller on ds kick panel. this will send signal to the light on the dash. Like I said mine is a 92 so I dont know where the abs default lies in here.
SO
start at the beginning.
when you shift to low, do you hear the relays in the kick panel engaging??
if not start with the test procedure in the fsm for this relay, I have it at work but not at the house.
if it is clicking it is probably ok.
now have someone you know well sit in the drivers seat and you slide under the truck. DO NOT TURN ON THE MOTOR!!!!!!! just turn on the ignition and have them engage the transfer. You should hear the motor engage for 1-2 seconds. if you dont then you have an issue either in the relay (wich you should be able to rule out with the fsm procedure) or the motor or the wiring to the motor. if it is moving then check the sensor at the front of the transfer test it and see where you are.

FWIW,
I have done all of this multiple times and still have not solved it. I am pretty sure I have a short somewhere but have not had tiem in the last 6 months to chase it down.
Dave

 

[TX_TLC]

Semlin,
Thanks for the links...I has missed a couple things in that first one.

I will try to short the switch tonight or tomorrow. Can I get anymore help in making sure I get the correct one? I know on Slee he says, "This is the switch located on the FRONT output side of the transfer case approximately at 11 o'clock when facing towards the rear of rig from the front." Can anyone tell me the color of the wires? or a picture would be awesome!

Thanks again for the help!