Quick fix for failed 4wd solinoid

[BILWFURIOSIL]

I have read all the information you all have posted on failed 4wd solenoids and found you all to be very informative. The problem I saw was that most of the solenoids found for replacement were either very expensive or were difficult to find. With this in mind, I came up with the easiest and no cost repair after some evaluation.

If, when the 2wd solenoid failed it reverted to 4wd, why not swap the failed 2wd solenoid for the good 4wd solenoid? It would then fail to 2wd not 4wd. With this in mind, I set about to reverse the electrical connections on the solenoids and the vacuum lines. Those smart Japanese put a plastic strip on the solenoid bodies so the electrical connections could not be interchanged. A quick snip with some toe nail clippers and the red connection fit on the blue solenoid and vise/verse. After switching the vacuum lines, I tested the modification out.

It worked perfectly, the only difference is that the 4wd switch now has 4wd on when in the off position and vise/verse. The repair took all of 10 minutes and cost nothing. The 4wd light still works in 4wd too.

This is for all those who have the same trouble. Good luck

 

[KLF]

This will get the truck out of 4WD, but now you can't shift into 4WD if you need it. The system doesn't have a "default" fallback mode, it just stays in the position that it was last shifted. The bad part about the design is that the 2WD solenoid stays energized all the time, unless you're in 4WD. They're all failing now as everybody is getting to the end of the design service life, about 20 years or so.

What I did with mine when the 2WD solenoid failed was get ahold of another pair of solenoids with a failed 2WD solenoid, but I took the good 4WD one and modified the socket as you had to do so the 2WD plug would go on it, bolted it on in place of my failed 2WD one and all was well.

 

[BILWFURIOSIL]

I actually switched the 2 solenoids wires and hoses leaving them both connected. Now the 2wd (failed) operates the 4wd (now default by failure) and the old 4wd solenoid operates the 2wd. It will in fact go into 4wd in high range, it will not however go into 4wd low when shifted through the transfer case. I still must find a replacement solenoid as if I need low I want to have it without switching the vacuum hoses.