![]() I cleaned out the old crud, packed it with fresh grease, reattached the boot, and left the whole thing sit while I reinstalled a pair of marker lights in the bumper. I got under the truck, removed the skid plates, pushed aside the rubber boot and saw that the grease, where the rod entered free-wheeling clutch housing (red arrow), was old and jelly-like. (That’s different from the Gen 1, which has auto-locking hubs.) Armed with that knowledge I looked up the actuator in the manual and noticed that it recommended greasing the actuator rod. ![]() Also, my mechanic explained to me that my Gen 2 Montero engages 4-wheel-drive by connecting the right-front axle shaft to the front differential by means of a vacuum-powered actuator. I had ordered the factory shop manuals for the truck a while back, so I decided to see if I could fix it myself. In the last couple of months though, the lights wouldn’t stop blinking, a sign that the system wasn’t able to engage the front axle. Normally I’d shift the transfer case lever into 4 High and the green lights in the instrument cluster, indicating the status of the front wheels, would blink (four-wheel drive engaging), then go solid (in four-wheel-drive). ![]() ![]() For the last couple years or so my 4-wheel-drive system has been engaging intermittently. ![]()
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