Converting Hubs on a push button 2005

Having experienced the 4x4 system failing on me while out yesterday I have been trying to read through all the threads on converting to manual hubs.

Please can I check my understanding.

1. I replace the hubs with manual locking ones.
2. When I now select 4wd the system will give me the flashing green 4x4 symbol because it won’t know the system has changed.
3. I need to permanently short out the wires on the grey vacuum sensor so the system thinks it has vac.

4. Operate 4wd and 4wd-l from cabin as required.

Oh yes and then I can remove all the vac pipes, solenoids and all that stuff, just blocking the manifold?

5. If I forget to switch manual hubs back to 2wd nothing too bad happens, just a bit less economic on fuel tyres etc?

Is that it? Or is there something more to it?

Apologies if a stupid question, but all the write ups seemed to be for lever based systems not the buttons.

Make sure to block the vacuum pipe that leads to the system from the manifold. Follow the pipes to the manifold and block the pipe at the first union.

You can then remove the whole system but remember to loop the vacuum ports on each hub, or block them, water can get into the hub otherwise.

Other than that, you've got it. Literally a 5 minute job to put the bypass in.

sniper

So on further investigation turns out that my failure caused by a wire broken of the front 4wd switch of the transfer box.

I fixed the wires back on and if somebody presses the 4wd button in the cabin and I manually press the button under the car the car goes into a mode where the green light flashes. But when I fit the button back into the box it does not work. So the issue is either the switch is faulty or the thing that ought to be pressing the switch is not pressing it.

So where to go next?

Switches are about £60, make sure to identify the correct one.

sniper

In reading around, it appears there may be a ball bearing behind the switch? Is that true? If so how big is it? I did not notice it falling out when I took the switch out and I don't think it is in there now (see pics below) and I cannot see it on the floor anywhere.

So my question is, if there is meant to be a ball bearing in there? If there is and it was not there, is there any way that the system could have worked, because at least for a few minutes it used to work a week ago.

Any advice would be really welcome as I am totally confussed about what is now going on.

But can you think of any way it could have worked without the BB being in there?

Cus something very strange is going on!

Yes I am beginning to think that is the only logical explanation. I am guessing given it was oily that it must have dropped out after I left to go fix the switch and is now lurking somewhere on the drive!

I have found some replacement ones on ebay (suzuki part number is 06111-10003 if anybody else has the same issue) and will stick one in and see what happens. I was really pleased to have fixed the switch with a bit of solder and some UV activated resin, but its all gone a bit flat now it does not owrk.

The ball baring is vital to the switch operating, if its not there then flashing lights etc.
The switch is a simple on off switch which you can test with a meter when off .
Best bet is to get one from a dealer.

hey god,68, please could you PM me a pick of the connector wires you said were
broken and the button under neath the car you said you press please.
ive had my 4x4 flashing for days and it wont go back to 2wd. i,m stuck with this problem too. i have manual hubs on thou. cheers , liam.

Hi,
If you look at the picture that Bryn sent it is part number 30.

I am afraid I am working away from home so can't nip out and take the pic you want.

But it is easy to see under the car, it is the front most switch on the transfer box, it has two pink wires coming out of it and has a blue plastic ring around a black cap. One of my pink wires was broken. I had to dismantle the switch by carefully cutting the blue and black bits off. I was then able to solder wires back onto the exposed stubs and seal the whole thing back up with UV activated resin. Off the car I was able to test the switch with a meter and it works. But on the car nothing has changed.

I am suspicious that in taking out the switch the little ball bearing has fallen out and so now when the 4wd button is pressed nothing happens.

I plan when back from holiday to get back under the car with a meter and test that when 4wd is selected that the button does in fact close, if it does not then it will I hope confirm that the BB is missing and I will drain down the box again, fit a new BB and see if that chamnges anything.

To be clear there is no switch you can press under the car without removing it from the transfer box first (and oil will come out when you undo the switch!).

Hope that makes sense.