Symptoms
On 2005-on trucks, the green 4WD light flashes (one owner counted 12 flashes) with a click, the 4L light may flash too, and 4WD won't engage even though the hubs lock when tested.
The fix, step by step
- First rule out the hubs and check the clutch is fully down (or the auto is in neutral).
- Then check the plugs and wiring on the transfer case.
- If they're fine, remove the round tin actuator cover at the back of the transfer case.
- One BigJimny owner found condensation and rust inside, cleaned and dried it, and it worked perfectly afterward.
- Watch for two springs that fly out when the armature comes out, and set the actuator's position relative to the selector shaft per Suzuki's procedure on reassembly.
- Change the transfer-case oil while you're there.
Tools & part numbers
- Basic hand tools
- contact cleaner
- service manual for the actuator alignment procedure.
Where to buy the parts
4WD SwitchBigJimny ↗Amazon ↗
Transfer Box Oil Seal Kit, JimnyBigJimny ↗Amazon ↗
Hunting a used or discontinued part? Search eBay Motors for Suzuki Jimny JB23 / JB43 parts →
Rated for a competent home mechanic with a decent tool kit. Confirm torque figures, fluids and procedures against the factory service manual for your VIN, support the truck on stands rather than a jack, and work at your own risk (disclaimer). Some parts links are affiliate links, which pay us a small commission at no cost to you.