Fj62 transfer case wires

[Spencerfj6289]

Hi I have a 1990 fj62 and wanted to see if anyone knows what this connector/wires do. I don't know whether they're supposed to be connected to the piece in the t case that I was pointing at, or whether they should be spliced together. The truck is stuck in 4wd and making some grinding Sounds, so trying to figure out what this part does and whether the wires connect to the part, or whether it was a single wire that broke and needs to be patched back together. Here is a link to the video

 

[Randy88FJ62]

If your truck is stuck in 4WD then your solenoid (VSV) went out on your passenger firewall.

Read here:
Writeup: 1988 FJ62 4WD Solenoid fix for $17.77

Regarding your inital video and question, read here:
FJ62 transfer case sensors, what are they?

 

[Spencerfj6289]

If your truck is stuck in 4WD then your solenoid (VSV) went out on your passenger firewall.

Read here:
Writeup: 1988 FJ62 4WD Solenoid fix for $17.77

Regarding your inital video and question, read here:
FJ62 transfer case sensors, what are they?

I have already replaced that part in an effort to fix this, but I still have the problem. I know I connect3d it all correctly because I marked the vacuum lines with tape to make sure.

 

[mwebfj60]

That's the 4 lo indicator.

 

[Spencerfj6289]

That's the 4 lo indicator.

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Ah thank you so much! Do you think this could keep it stuck in 4 or cause any grinding if it were disconnected? The wire was probably broken while in 4wd on a trail, so maybe it could have it still locked in 4?

 

[mwebfj60]

When you put the shifter in Low, it over rides the 2/4 switch in the dash and sends 12V to the blue VSV to put it in 4wd. This switch does that. You can test for 12v at the VSV, and see which one has voltage. Blue is 4wd, red is 2wd.
You can splice those ends together to simulate a 2wd indication if you don't need 4wd, otherwise, just switch the output lines on the VsVs( the ones that go down to the transfer case) to go from 2 to 4wd and back.

Edit...When the switch is depressed (shifter in 4lo) you get continuity.

 

[mwebfj60]

I was getting some odd readings while testing this one so had to take it apart. The contacts were very dirty.

 

[mwebfj60]

Ah thank you so much! Do you think this could keep it stuck in 4 or cause any grinding if it were disconnected? The wire was probably broken while in 4wd on a trail, so maybe it could have it still locked in 4?

So, no, those wires being open wouldn't cause you to be stuck in 4wd. Sorry about that and Thanks for helping me find that my switch had a problem.

 

[4Cruisers]

I was getting some odd readings while testing this one so had to take it apart. The contacts were very dirty.

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Sorry to hijack the thread but I have a simple question - after taking the switch apart to inspect (and clean) it, were you able to put it back together again, or is that a destructive procedure? I put the transfer case from my '89 FJ62 donor vehicle behind a new H55f in my '86 FJ60, and wired the L4 indicator switch to a new indicator light in my dash. The light comes on intermittently and I'm thinking it's the switch.

 

[mwebfj60]

Sorry to hijack the thread but I have a simple question - after taking the switch apart to inspect (and clean) it, were you able to put it back together again, or is that a destructive procedure? I put the transfer case from my '89 FJ62 donor vehicle behind a new H55f in my '86 FJ60, and wired the L4 indicator switch to a new indicator light in my dash. The light comes on intermittently and I'm thinking it's the switch.

The tabs bend out...reluctantly, then the insulator slides out. Put it all back together and squeezed and shaped them back around to hold it back in. Seems good to go. Unfortunately for @Spencerfj6289 I don't see a way to fix the wires being broken off where they are. It may be possible to dig out around the wires to expose enough to solder but doubtful.

 

[4Cruisers]

Thanks, I might go ahead and disect mine.

 

[Spencerfj6289]

The tabs bend out...reluctantly, then the insulator slides out. Put it all back together and squeezed and shaped them back around to hold it back in. Seems good to go. Unfortunately for @Spencerfj6289 I don't see a way to fix the wires being broken off where they are. It may be possible to dig out around the wires to expose enough to solder but doubtful.

The tabs bend out...reluctantly, then the insulator slides out. Put it all back together and squeezed and shaped them back around to hold it back in. Seems good to go. Unfortunately for @Spencerfj6289 I don't see a way to fix the wires being broken off where they are. It may be possible to dig out around the wires to expose enough to solder but doubtful.

 

[Spencerfj6289]

I am soldering mine back together. That's the only way I've found to repair it. I'll post picks of the repair when I'm done.

 

[Spencerfj6289]

This is before

 

[Spencerfj6289]

I have it soldered now, and I'm gonna give it a liberal dose of 5 minute epoxy to keep it all together nicely and minimize vibration on the connection. Hopefully it'll do something lol.

 

[Spencerfj6289]

Here it is getting a heavy dose of flexible epoxy to hold everything together. Next I'll just put some wire loom around those wires and reinstall it.

 

[mwebfj60]

Very nice. Good work.

 

[Spencerfj6289]

Anyone that might have an idea why it's staying in 4 and grinding intermittently, I'd be eternally grateful lol. I've replaced the blue and red solenoid (made sure vacuum lines went on in the same location by marking them with tape), made sure the hubs are free by jacking up the truck and spinning both wheels by hand. So I know the transfer case is still in 4. Not sure whether it's 4hi or lo, but definitely in 4.

 

[mwebfj60]

If you have a mighty vac, you can pull the line off the red VSV that goes to transfer case, hook the vac to it, it should hold pressure after about 15 pumps and disengage the 4wd. If it doesn't hold vacuum, more than likely the soft or hard lines, the diaghragm is very stout.
If it does hold vacuum but doesn't release to 2wd then the internal linkage is hanging up.

 

[Spencerfj6289]

If you have a mighty vac, you can pull the line off the red VSV that goes to transfer case, hook the vac to it, it should hold pressure after about 15 pumps and disengage the 4wd. If it doesn't hold vacuum, more than likely the soft or hard lines, the diaghragm is very stout.
If it does hold vacuum but doesn't release to 2wd then the linkage is hanging up.

I understand putting pressure on it to test it. That makes sense. I don't know what that vac you're talking about is though. And is the linkage cable activated?