[Hermida]

Hello,

I recently purchased a Suzuki Jimny (Vin: JSAFJB43V-------). This is my second Suzuki 4x4 after a Samurai I had like 20 years back then sold to a friend. This Jimny has an electronic traction control allowing the driver to select between 2WD, 4WD & 4WD-L through three buttons on the dashboard. I realized that it is permanently on 4WD, it doesn’t engage 2WD or 4WD-L anymore . When turning, the front tires are hooking. I work in Nigeria and here there are no serious Suzuki workshops, most of the repairs I do them myself but now I have an electronic issue… I have been looking on the internet to see if I could download the service manual of this Jimny, I found only one site that have a free link to a PDF file but it goes up to section 6. Section 7 is not included and that is the one for the gearbox and transfer. I have paid to download from five different websites the Jimny service manual, none of them include the electronic transfer case type but only the manual transfer case… I would like to know the part number of the repair manual for the Suzuki Jimny with electronic transfer case, hopefully MR. GOOGLE could help me find the correct one to download!!!
Otherwise if there is no other solution, is it possible to convert the electronic transfer case to manual one with a kit or to replace the electronic transfer with a manual one?

Thanks a lot for any info!

Kind regards.

Alex.

[rustyzook]

Have you checked the selector solenoid/motor? Might be a place to start, I've never looked at a jimny Tc, however a mate of mine has a hilux with an electronic case,msometimes the selector motor will jam and leave him locked in 2wd or not able to lock in 4wd.

I think you can get a Sierra transfer into a jimny, however ratios would be all wrong and so,e floor cutting would be needed

[Hermida]

Hi RUSTZOOK,

After browsing for hours, days, weeks, months, I have finally got a link to download the service manual of the transfer case of the electric transfer case. I followed the troubleshooting steps on the manual and finally arrive to the conclusion that the actuator in the case is bad (Picture attached).
Thanks for your advice.
Alex.

[losfer]

The transfer shift control and hub locking on the pushbutton jimny is the most complicated system ive ever seen on a suzuki , it is so stupidly over-complicated . The design engineer has been rumoured to have bought 2 islands in the bahamas and have several offshore bank accounts.

You have a 4wd ecu which monitors everything and only allows it to change providing all requirements are met including having the brake pressed , the clutch pressed and the atmospheric pressure is between 1004 and 1020 while licking the passenger window .

You have a vacuum switch which tells the ecu it is seeing engine vacuum and 2 solenoids for locking and unlocking the hubs , vacuum lines and then of course the vacuum operated hubs which uses the wheel bearing locking nut to seal on !

both the 4wd switches on the transfer have to be in full operating condition before the ecu will allow it to operate and then the actuator itself which is a common source of failure (not according to another overseas popular forum !!!).

I had the same trouble when trying to diagnose the exact point of failure on these systems , the only workshop manuals available do not cover the pushbutton system.

If the OP does happen to return for help i have a complete diagnostic procedure for the pushbutton system which used to be available online but i cannot find it anymore! Its hidden deep within all the other paperwork in my shed!

[Hermida]

You are right the repair manual doesn't have the push button. In my Jimny we have realized that even the wiring have been tampered, cables are cut, relays are added... A big problem. If you can help with your info it will be fantastic!

[losfer]

No prob will get back to you tomorrow , im heading off to do a job soon . Ill find the paperwork in my shed and scan it.

[prolecs]

Losfer, is that electric transfer case info available?

[prolecs]

Well I dived in to see what I could do with the 4WD system on my "new" Jimny 2010 with 1.5L motor and manual hubs fitted. 4WD and Lo Range flashing randomly and can't select either. Some noise from the electric motor when I try 4WD so it is trying. Drives in 2WD ok and the flashing lights come and go without any apparent issue.
Checked transfer case "ball bearing" switches. One with a suspect lead that had been damaged and corrosion eaten it away right at the switch head. Managed to clean up and solder the wire back on, but no change.
Removed the wiring plug to the vacuum switch and shorted the wires to the computer (more info on the web about doing this but essentially if manual hubs, blank the vacuum off at the manifold, disconnect and loop a short tube on the two hub connections each wheel (to keep water out of the hub bearings). I looped the tubes back to the chassis pipes as well to keep dirt out of the piping).
Took the motor/gearbox drive off, (drain the transfer box oil FIRST) but did not know to check the gear position to selector shaft position, under the triangular cover. Bugga! So if you are going to do this, put the thing in 2WD, photo where the mark on the cog sits relative to the last tooth at front end of shaft (or paint a spot on the shaft). (I THINK it does not line up with a tooth, but is two gear teeth past the last shaft tooth). Cleaned up the motor and cover (rusted inside cover so rust remover, and epoxy paint). Beware there is a ball bearing each end of the motor shaft! Cleaned commutator and re-greased shaft with a little silicon grease. Got it back together eventually! Found a spring on the floor about 10mm diam, very light - don't know if it came out of this!!
My selector shaft moved in and out manually (rag and multigrips on the shaft) so box is mechanically fine. Beware, the selector shaft rotates, and the two ball bearing switches do NOT operate unless the shaft is exactly in the correct point of rotation. Seems VERY touchy.
Fitted it back on the box. Played with cog under the triangular cover a bit. Took a punt from info on the web, and set as I suggested above.
I can now get modes 2WD, 4WD, Lo Range, (with indication), and drive the thing in any mode. However, in 2WD, the lights still flash after a short delay and lock out any button operation until I turn ignition off, and start again.
So its not perfect yet but I can use it. Maybe my gear alignment is not correct. Doubt it's the ball bearing switches, in 2WD I don't think either ball bearing switch operates, and the vacuum switch is out of circuit. So what triggers the computer to flash the lights?
Maybe a motor position switch under the plastic cover of the selector motor gearbox is not giving the signal for home??? Or alignment of that gear and shaft is still not right.
Any help appreciated!!

[losfer]

im still yet to dig the paper work out of my shed.

The trick with realigning the gear is .... whatever the dash is displaying which range the transfer is in , you must also manually select the transfer shift rod to that range before inserting the gear. if the 4wd ecu is seeing its in 4 low , and the switches on the transfer are telling the ecu its in 4 high then if you put the gear in in this position it wont work.

the computer sees signals from both the switches on the transfer , the vacuum switch from manifold vacuum (near the lock and unlock solenoids) and the actuator motor position.

so when you say the lights flash im guessing its flashing a 4wd light. if the gear is inserted correctly i would probably be looking at one of the switches on the transfer.

[Hermida]

Hi all,

What is the part number of the cable attached to the actuator?

Cheers.

Alex.

[Hermida]

Hi all,

What is the part number of the wire attached to the actuator? One side of that wire have a long plug that connect to the actuator. The other side of the wire have a smaller plug that connect to the harness of the vehicle. They are 6 cables on that wire.

Regards.

Alex.

[pete_79]

This thread has the manual that you are all looking for.
There's also a heap of photos of the selector and actuator that might help with some of your other questions as well.

http://auszookers.com/forum/viewtopic.php?t=49478#p866584

[Hermida]

Wow, what a great job... Is a pity that here the Suzuki dealers are only concentrated in selling cars but not maintaining them! They don't even have filters for basic maintenance!

Cheers.

Alex.

[pete_79]

No worries mate.
It's a pity there aren't so many people in here trying to help others with Jimny questions these days.

The PDF in that thread has all of the manuals and the wiring diagrams. I can't remember exactly which one has the push button transfer case details, but it's one of the last ones on the list.

[Hermida]

Hi Pete,

There are no links to any manual in that tread. I wanted to post a picture of the wire I am talking about but I cannot do it on this forum. That wire can be seen many times in the pictures on that tread. Is the one attached into the actuator of the transfer case. I have purchase a new actuator, part of my problem have been solved but still have some issues till I realized that some cables of that wire do not have continuity. Could try to repair but the damage is too close of the plugs. I have been in touch with two Suzuki dealers and no one have a clue about the wire. They are only telling me that the wire is sold with the actuator... Then why did you sell me the actuator without the wire???? If I could have that part number it will be different.

Cheers.

[watermouse]

Hermida wrote:

I wanted to post a picture of the wire I am talking about but I cannot do it on this forum.

Upload your picture to Imgur (no account needed), click on "Get Share Links", copy the "BBCode", paste it in your next post

[Hermida]

In Pete_79's tread, we can see many pictures of the actuator and in most of them is possible to see the wire attached to it. This is one picture from that treat of the actuator with that wire: http://i844.photobucket.com/albums/ab10 ... 9iemsr.jpg

[Hermida]

In this picture we can see the wire disconnected from the actuator: http://i844.photobucket.com/albums/ab10 ... oyxvph.jpg

[Hermida]

I don't see how to upload a picture... I did what watermouse suggested to do but it does not work...

[pete_79]

This is the link from that thread.
Click to download Suzuki Jimny Manual

So I understand you have snapped all (or some) of the wires on the main plug, correct?

[Hermida]

A rock brushed and affected the actuator, the wire and the two sensors on the transfer case. I realize there was a problem when I could not remove the 4x4 and the front wheel were blocked making it difficult to turn. I decided then to take it to a Suzuki dealer, they decided to eliminate the TCM cutting all wires going to it and replacing all with two relays!!! A great disaster... I am working on this issue for the past 6 months.

[Hermida]

Now I am working on a metal plate that will protect the transfer case and those vital parts...

[Hermida]

I have just downloaded the manuals! Thanks pete_79!!!

[pete_79]

Hermida wrote:

A rock brushed and affected the actuator, the wire and the two sensors on the transfer case. I realize there was a problem when I could not remove the 4x4 and the front wheel were blocked making it difficult to turn. I decided then to take it to a Suzuki dealer, they decided to eliminate the TCM cutting all wires going to it and replacing all with two relays!!! A great disaster... I am working on this issue for the past 6 months.

Wow, ok.
Do you have any wrecking yards over there that you could go and get that whole wiring lume off another transfer case?
It was a while ago that I worked on my case and I can't remember exactly, but I'm pretty sure it should all come off in one piece.
I'd be getting rid of that crap from the dealers and connect it all up properly, as others have said earlier, the ecu will be going nuts with some odd relays in there.

[prolecs]

The next installment to the flashing lights.

The electric pinion alignment is correct as shown by pete_79 in his excellent write-up.
I found one solenoid was not operating (full of crap) but probably not causing this problem, a lot of TLC and it works ok now. The vacuum switch is working ok. You can actually suck on the hose and get it to operate.

So I wired in a selection of LEDS to the 4WD controller, on a harness so LEDs sat on the dash. Not for the feint hearted as you have to solder directly to the printed circuit board - transfer switches*2, motor switches*3, clutch sw and vacuum switch. Now I can see what's doing!!!

The transfer switches are not faulty. The motor switches all work when they should. The clutch switch is working (but I have no idea what it does).
One fault found was the non-return valve in the vacuum line. I replaced it with something off an Astra I had at hand. Still got the flashing lights with only the vac switch hooked to the manifold vacuum, but the switch operates soon after I start the engine. I can select all modes ok.
Everything appears to do what it should, but still flashing lights.

Then it dawned on me
Standard, the vac switch is piped to the VSV2 solenoid, so it only operates when the 4WD is selected and that solenoid operates. The controller is looking for A CHANGE IN STATE from the vacuum switch within a defined period after that solenoid operates. Probably looking for a rising edge for the electronic minded folks out there. So bridging the switch will NOT fix the problem. The VAC switch must switch (on - effectively bridge the two vac switch wires) after the VSV2 solenoid operates.
So I hook up the VSV2 solenoid to the vacuum switch and no more flashing lights

I could not find a wiring diagram to suit my 2010 model transfer system so I have drawn up my own. When I tidy it up (a big job!), I will put on here.

[miki_E]

[quote="losfer"]im still yet to dig the paper work out of my shed.

Did you find these instructions yet Losfer?