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MiN
Extreme Veteran
Date registered: May 2006
Location: Alpujarras, Spain
Vehicle(s): No cars, at all.
Posts: 555
| Re: '02 G500 Differential Lock System
To see if they're working properly, disconnect the diff lock actuator from the axle and then, with the engine running get someone to press the centre and rear switches while you watch the diff lock actuator. Yu should see the pin move, slowly the full length of the actuator opening. Press the diff lock switch again and it should move slowly back to the start position. |
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Re: '02 G500 Differential Lock System
MiN - 4/8/2011 9:57 AM To see if they're working properly, disconnect the diff lock actuator from the axle and then, with the engine running get someone to press the centre and rear switches while you watch the diff lock actuator. Yu should see the pin move, slowly the full length of the actuator opening. Press the diff lock switch again and it should move slowly back to the start position.
Sounds like a reasonable starting point ... |
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Re: '02 G500 Differential Lock System
After much testing and podding, it appears that the solenoid for the rear locker is getting rapid, intermittent power from the switch pack on the dash. The mechanic (first time on a G locker system) and I worked through the entire system and that seems to be the only trouble spot ... Thoughts? Sound familiar? |
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Re: '02 G500 Differential Lock System
After checking a piece that W5YK (Richard R) posted (link on my links page) and then sending him an email, he has pointed me to a fault in the switch pack that causes the condition with the front and rear locker ... Will report back soon ... |
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Re: '02 G500 Differential Lock System
With the actuator unbolted, it cycles just fine. When reinstalled, it does not cycle ... I'll have to jack it up and see if everything works without stress on the system ... |
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fernweh
Date registered: Apr 2006
Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany
Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa
| Re: '02 G500 Differential Lock System
Indiana Drew - 4/10/2011 9:55 AM
With the actuator unbolted, it cycles just fine. When reinstalled, it does not cycle ... I'll have to jack it up and see if everything works without stress on the system ...
Drew,
when you have the actuator removed and the both wheels are off the ground, you should be able to slide the lock with a screwdriver into the engaged position - very easily, but remember you have to turn the wheel - against the other - for the lock to line up.
Again, it should slide very easily!
Good Luck,
Karl
Edited by fernweh 4/10/2011 10:00 PM
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Re: '02 G500 Differential Lock System
fernweh - 4/10/2011 8:59 PM Indiana Drew - 4/10/2011 9:55 AM With the actuator unbolted, it cycles just fine. When reinstalled, it does not cycle ... I'll have to jack it up and see if everything works without stress on the system ... Drew, when you have the actuator removed and the both wheels are off the ground, you should be able to slide the lock with a screwdriver into the engaged position - very easily, but remember you have to turn the wheel - against the other - for the lock to line up. Again, it should slide very easily! Good Luck, Karl
Thanks Karl I'll have to get a helper or longer arms ... |
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fernweh
Date registered: Apr 2006
Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany
Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa
| Re: '02 G500 Differential Lock System
Indiana Drew - 4/10/2011 7:22 PM
fernweh - 4/10/2011 8:59 PM Indiana Drew - 4/10/2011 9:55 AM With the actuator unbolted, it cycles just fine. When reinstalled, it does not cycle ... I'll have to jack it up and see if everything works without stress on the system ... Drew, when you have the actuator removed and the both wheels are off the ground, you should be able to slide the lock with a screwdriver into the engaged position - very easily, but remember you have to turn the wheel - against the other - for the lock to line up. Again, it should slide very easily! Good Luck, Karl
Thanks Karl I'll have to get a helper or longer arms ...
what's wrong with your legs? |
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Re: '02 G500 Differential Lock System
fernweh - 4/10/2011 11:39 PM Indiana Drew - 4/10/2011 7:22 PM fernweh - 4/10/2011 8:59 PM Indiana Drew - 4/10/2011 9:55 AM With the actuator unbolted, it cycles just fine. When reinstalled, it does not cycle ... I'll have to jack it up and see if everything works without stress on the system ... Drew, when you have the actuator removed and the both wheels are off the ground, you should be able to slide the lock with a screwdriver into the engaged position - very easily, but remember you have to turn the wheel - against the other - for the lock to line up. Again, it should slide very easily! Good Luck, Karl
Thanks Karl I'll have to get a helper or longer arms ... what's wrong with your legs?
 Well its more difficult to hold the screwdriver with feet than hands ...  |
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Otiswesty
Administrator
Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
Posts: 3003
| RE: '02 G500 Differential Lock System
Short term fix for locker issues
 (Frnt-Lckr.jpg)
Attachments
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 Frnt-Lckr.jpg (202KB - 2 downloads)
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Update: '02 G500 Differential Lock System
Today I jacked up the front end with the center and rear diffs locked and the front with only the amber light showing. It has felt like the front has been locking but no red light. I found cycling the front diff button, the front is locking and unlocking, but the red light is not coming on!!! I did replace the check valve (how do you get the plastic vacuum line all the way over the ends of the new one???) but I suspect that it was OK and I'll save the old one. When I take it in to have the parking brake cable replaced, I'll have them inspect the wiring. I suspect the locker is not traveling to a limit that signals the red light as I believe with the locker unbolted and hanging by the axle, the red light does cycle on when the button is engaged ... Oh so close to everything working in that system ... |
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Fernando BR
Date registered: Jan 2007
Location: Brasil
Vehicle(s): G500/05 300GE/91 300GD/80
| Re: '02 G500 Differential Lock System
I did same test on my 460 . yes they are different but not in the concept. So i took slave out and with it on my hand pull the lever (press the swith) , red light on at dash and slaver cylinder axels at engage position. Left all in that position . Lift left wheel ( on a secure way) went under the truck and with a screw moved the locker to the diff direction, a friend of mine turn left wheel and before second turn " CLIC!!" its locked. Then i install the cylinder with red light on at the locked axel(right position). I was in a place that i could drive 100 mts streat with all locked , after that I desengage lever and drive back (R) .....unlocked...Did a good 1 liter fluid bleed and all ok after that.
Edited by Fernando BR 4/18/2011 3:43 PM
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W5YK
Extreme Veteran
Date registered: May 2006
Location: San Diego
Vehicle(s): 2002 G500, Unimog U2450,
Posts: 543
| RE: Update: '02 G500 Differential Lock System
Indiana Drew - 4/18/2011 11:46 AM
(how do you get the plastic vacuum line all the way over the ends of the new one???)
It's not easy, but one of these tools helps...
 (IMG_0971b.jpg)
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IMG_0971b.jpg (117KB - 0 downloads)
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Re: '02 G500 Differential Lock System
It looks like I save frustration if I have the mechanic do it ... |
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MiN
Extreme Veteran
Date registered: May 2006
Location: Alpujarras, Spain
Vehicle(s): No cars, at all.
Posts: 555
| Re: '02 G500 Differential Lock System
Drew, if the front locker is engaging but the red light is not illuminating, it could be the electric switch on the hydraulic cylindar that's at fault. This exact symptom happened to me, though on the rear axle.
Swap the rear electric switch with the front one and repeat the diff lock engagement process on centre and rear diffs. If the rear difflock light goes red with the front diff electric switch in it, then you know the electric switch at the cylindar is ok. |
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fernweh
Date registered: Apr 2006
Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany
Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa
| Re: '02 G500 Differential Lock System
MiN - 4/18/2011 8:20 PM
Drew, if the front locker is engaging but the red light is not illuminating, it could be the electric switch on the hydraulic cylindar that's at fault. This exact symptom happened to me, though on the rear axle.
Swap the rear electric switch with the front one and repeat the diff lock engagement process on centre and rear diffs. If the rear difflock light goes red with the front diff electric switch in it, then you know the electric switch at the cylindar is ok.
Good Idea - but it will not work with a 2002 G-500 - a single switch pack, no separate switches....
Karl |
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Re: '02 G500 Differential Lock System
fernweh - 4/18/2011 10:49 PM MiN - 4/18/2011 8:20 PM Drew, if the front locker is engaging but the red light is not illuminating, it could be the electric switch on the hydraulic cylindar that's at fault. This exact symptom happened to me, though on the rear axle. Swap the rear electric switch with the front one and repeat the diff lock engagement process on centre and rear diffs. If the rear difflock light goes red with the front diff electric switch in it, then you know the electric switch at the cylindar is ok. Good Idea - but it will not work with a 2002 G-500 - a single switch pack, no separate switches.... Karl
I believe it is either the witch at the actuator, a wiring problem or the actuator being out of whack ... |
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MiN
Extreme Veteran
Date registered: May 2006
Location: Alpujarras, Spain
Vehicle(s): No cars, at all.
Posts: 555
| Re: '02 G500 Differential Lock System
Karl, I'm not talking about the switch pack, I'm talking about the individual switch on each 'hydraulic cylindar'. These go bad and even though your diff may be engaged, a bad switch on the cylindar won't send the signal to the red light on the in-cabin switch pack.
Drew, just try it. Unplug the electric cable at the cylindar, remove the big brass switch housing and swap it with the one on the rear diff. Then try the rear diff actuation again. If the red light comes on for the rear diff, you'll know the swich at the 'cylindar' works. If it doesn't work, and the diff is definately engaged, you'll know it is the switch on the cylindar that isn't working. |
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Re: '02 G500 Differential Lock System
MiN - 4/19/2011 1:17 AM Karl, I'm not talking about the switch pack, I'm talking about the individual switch on each 'hydraulic cylindar'. These go bad and even though your diff may be engaged, a bad switch on the cylindar won't send the signal to the red light on the in-cabin switch pack. Drew, just try it. Unplug the electric cable at the cylindar, remove the big brass switch housing and swap it with the one on the rear diff. Then try the rear diff actuation again. If the red light comes on for the rear diff, you'll know the swich at the 'cylindar' works. If it doesn't work, and the diff is definately engaged, you'll know it is the switch on the cylindar that isn't working.
Will give it a try! Thanks ... I can say the rubber boot on that wiring is split ... |
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Indiana Drew
Expert
Date registered: Feb 2007
Location: Houston Tx
Vehicle(s): 2002 G500 LWB, 1980 280GE SWB (Sold), S500
Posts: 2223
| Solved: '02 G500 Differential Lock System
Victory!!! Thank your Richard, Karl and everyone else!
What I found:
- The banjo fittings at the locker actuators, front and back, had grown closed with gunk from lack of use.
- There was a problem in the switch pack that cycled the rear locker (and therefore the front) on and off too fast for the rear red light to go off, but not allowing the front locker to lock. That was intermittent. By using part of Richard's switch pack mod that was fixed and now my rear locker works independent of the center ...
- The front locker was locking, but the red light was not showing it locked. When of the axle the actuator worked fine and the light on the switch pack worked. Using Karl's suggestion I jacked up all 4 wheels, engaged the front locker with a screw driver, engaged the actuator and reinstalled it pushing it to the passenger's side (LHD) while tightening it.
- I also replaced the check valve in the vacuum line.
We went to check out an off road park near Houston and the system worked as it should mostly. The front was still a bit slow to engage but did it all afternoon. I'm not sure if there is a way to adjust the indicator switch in the actuator, but that still might be fussy ...
Again, thanks to all who have offered suggestions. I now feel pretty comfortable with how the system functions. |
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