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Transfer Case in Neutral - let's get scientific
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Posted 12/20/2011 6:11 PM
thanito
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Date registered: Aug 2009
Location: Greece
Vehicle(s): MB G400CDI, MB 300E-24, Mini Cooper S
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Re: Transfer Case in Neutral - let's get scientific

Yet still, the motor works for a while every time you start the engine to check the position,right?
There is one thing that I cannot understand though: WHY there are times that while driving you feel a big clunk and the TC goes in neutral? Since this motor only works when engine starts and when you use the H-L button?
#198309 - in reply to #156120
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Posted 1/3/2012 9:57 PM
krnnerdboy
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Date registered: Aug 2011
Location: los angeles
Vehicle(s): 02 g500, 640 gran coupe, f30, m6, gt3
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Re: Transfer Case in Neutral - let's get scientific

thanito - 12/20/2011 3:11 AM

Yet still, the motor works for a while every time you start the engine to check the position,right?
There is one thing that I cannot understand though: WHY there are times that while driving you feel a big clunk and the TC goes in neutral? Since this motor only works when engine starts and when you use the H-L button?


Good question, and the only thing I can deduce is that it was never fully in gear and the driving loosens the position of the transfer case
#198682 - in reply to #198309
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Posted 1/12/2012 9:59 PM
TCao



Date registered: Jul 2008
Location: San Diego CA
Vehicle(s): 2002 G500
50
RE: Transfer Case in Neutral - let's get scientific

Had my first experience with the dreaded TC in neutral fault message today (2002 G500 with ~71k miles). I was able to reset by toggling the H/L switch a few times to get the TC to switch to H (I heard the TC electric motor grinding away and the TC thunked into L before it was able to switch to H). I intend to install a new TC motor to be on the safe since AFAIK, this motor has not been replaced by the previous owners. Just wanted to say thank you for all the great info provided in this thread.
#199016 - in reply to #156120
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Posted 1/13/2012 3:24 PM
Otiswesty
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Date registered: Jun 2007
Location: Portland, Oregon
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Re: Transfer Case in Neutral - let's get scientific

I have had a couple of issues recently
My TC indicator was blank again, but otherwise fine, no neutral spells. I could still shift between H and L but with a power cycle the indicator would blank out again. The TC control module had been updated to a gen 3 version a couple of years ago when I previously had issues with the TC in neutral.

Also, last winter in Baja I was having a temporary problem with my lockers not working. We fixed this by cleaning the contact at the electro-vaccuum actuators on the firewall and they worked fine for the rest of the 3 month stay. The locker problem recurred this Fall and I had plans to do some work myself like replace the TC shift motor and the dual locker actuator.

Since I was due to for a Service B (and it was 27 degrees outside) I decided to mention it at the dealer. They found that the TC locker was bad and dead to current. They thought this would solve both conditions but only fixed the TC. The vaccuum system had a bad check valve and the pump was running full time even with the check valve replaced. They replaced the vac pump and both rear lockers work like new.

So just want to point out that it is not always the shift motor, and I'm glad I didn't just throw parts at a problem that I did not fully understand. Just sayin'
#199067 - in reply to #199016
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Posted 1/13/2012 3:51 PM
fernweh



Date registered: Apr 2006
Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany
Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa
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Re: Transfer Case in Neutral - let's get scientific

otiswesty - 1/13/2012 12:24 PM

I have had a couple of issues recently
My TC indicator was blank again, but otherwise fine, no neutral spells. I could still shift between H and L but with a power cycle the indicator would blank out again. The TC control module had been updated to a gen 3 version a couple of years ago when I previously had issues with the TC in neutral.

Also, last winter in Baja I was having a temporary problem with my lockers not working. We fixed this by cleaning the contact at the electro-vaccuum actuators on the firewall and they worked fine for the rest of the 3 month stay. The locker problem recurred this Fall and I had plans to do some work myself like replace the TC shift motor and the dual locker actuator.

Since I was due to for a Service B (and it was 27 degrees outside) I decided to mention it at the dealer. They found that the TC locker was bad and dead to current. They thought this would solve both conditions but only fixed the TC. The vaccuum system had a bad check valve and the pump was running full time even with the check valve replaced. They replaced the vac pump and both rear lockers work like new.

So just want to point out that it is not always the shift motor, and I'm glad I didn't just throw parts at a problem that I did not fully understand. Just sayin'


Eric,
The vacuum pumps runs all the time when the the center diff is activated - regardless of the check valve

The check valve replacement made a big difference in my truck as well.

Are you then ready for another Baja Adventure?

Karl

Edited by fernweh 1/13/2012 5:23 PM
#199068 - in reply to #199067
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Posted 1/13/2012 7:39 PM
Otiswesty
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Date registered: Jun 2007
Location: Portland, Oregon
Vehicle(s): 463.241, 461.213
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RE: Transfer Case in Neutral - let's get scientific

Ya, driving to LA at the end of month and over the border feb 11th or so



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#199082 - in reply to #156120
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Posted 1/13/2012 9:44 PM
fernweh



Date registered: Apr 2006
Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany
Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa
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RE: Transfer Case in Neutral - let's get scientific

otiswesty - 1/13/2012 4:39 PM

Ya, driving to LA at the end of month and over the border feb 11th or so


Cool, I might join you. Going to La Ventana again?
#199089 - in reply to #199082
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Posted 3/5/2012 3:38 PM
krnnerdboy
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Date registered: Aug 2011
Location: los angeles
Vehicle(s): 02 g500, 640 gran coupe, f30, m6, gt3
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Re: Transfer Case in Neutral - let's get scientific

update:
symptoms: H/L box was always empty after a reset and a couple drives, and I had a couple pop in to neutral moments

fix:sent it out to rockauto to have my transfer case motor rebuilt.

They have since returned the motor to me untouched b/c they said they could find no faults. I have since installed the unit and I haven't had any issues for over a month. I'm thinking it was the connection that had built up some corrosion
#201218 - in reply to #156120
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Posted 4/23/2012 6:26 PM
capdenuit
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Date registered: Apr 2012
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Vehicle(s): 2002 G500, 1984 230e, 1969 280SL
Posts: 4

Re: Transfer Case in Neutral - let's get scientific

How about if servo motor was replaced in 2009 (on a 2002G) with 35kmi but not module ?
Should I replace both now (60kmi)?
#203093 - in reply to #156120
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Posted 4/23/2012 7:27 PM
DUTCH
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Date registered: Apr 2006
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capdenuit

You have a PM.
#203094 - in reply to #203093
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Posted 5/1/2012 5:34 PM
Balto
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Date registered: Mar 2012
Location: Scottsdale, AZ
Vehicle(s): 2002 G500
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RE: Transfer Case in Neutral - let's get scientific

Well I've had my 2002 G500 for a couple weeks now and a couple of days ago I got the Transfer Case in neutral! Without even knowing what to do I got it back very easy!

Today it happened again and I put it in neutral and hit the high/low switch and it was fixed. So it seems like it's not bad to fix BUT has happened a couple of times in the last few days so I'm guessing my motor needs replaced! I haven't checked the connections yet and plan to tackle that in the next couple of days.

Anyways,
I found a motor at Orielys auto parts for a couple hundred bucks! It's a refurbished one but has a lifetime warranty!

Here is a link:
http://www.oreillyauto.com/site/c/detail/A1C0/481001/03192.oap?year...

The only problem is that it only came up if I searched for a 2004 G500 and when I searched for a 2002 G500 nothing showed up! So do you think this one would work fine for my 02?

Thanks
#203230 - in reply to #156120
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Posted 5/1/2012 8:57 PM
4x4abc



Date registered: Apr 2006
Location: La Paz, Baja California, Mexico
Vehicle(s): 02 G500
5000
RE: Transfer Case in Neutral - let's get scientific

the motor rarely ever goes bad - it's the old style plastic gears you have to worry about

your only solution is a new unit from MB, since nobody here has found a source for the gears only yet
#203243 - in reply to #203230
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Posted 5/1/2012 9:32 PM
Balto
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Date registered: Mar 2012
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Re: Transfer Case in Neutral - let's get scientific

So the one I linked would not work? What is the difference between that one and MBs?
#203244 - in reply to #156120
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Posted 5/1/2012 9:35 PM
oskar
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Date registered: Sep 2006
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Vehicle(s): 1981 280GE, 2002 G500, 280SE 4.5, Audi A4 1.8T
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RE: Transfer Case in Neutral - let's get scientific

4x4abc - 5/1/2012 5:57 PM

the motor rarely ever goes bad - it's the old style plastic gears you have to worry about

your only solution is a new unit from MB, since nobody here has found a source for the gears only yet


seems to be a common problem these days. My new unit is coming in tomorrow :-(

Oskar
#203245 - in reply to #203243
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Posted 5/1/2012 9:52 PM
BonitaBeast
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Date registered: Mar 2012
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Re: Transfer Case in Neutral - let's get scientific

I think it's been a problem since the change over from a manual transfer case switch to the electronic tc switch with motor.

They have since updated the transfer case motor servo gears and updated the Transfer Case module (about 6 times I believe for the module).

I replaced my Transfer Case servo motor without drama and the H hasn't disappeared for a few weeks now. The TC moduile installation is another story though. I am having problems getting my ecu recognizing the new TC module. I am hoping it's a faulty module and my supplier will replace it for me. Keeping my fingers crossed.

#203246 - in reply to #156120
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Posted 7/12/2012 4:38 AM
BonitaBeast
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Date registered: Mar 2012
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Vehicle(s): 2003 Kleemann G55k, 2003 DINAN E39 M5
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Re: Transfer Case in Neutral - let's get scientific

Just an update on my Transfer case module drama. It turns out the Star Diagnostics my mechanic was using had not been updated to the latest software update so it was not recognizing the new Transfer Case Control module I got from Vlad. The Part I got from Vlad is the latest TC Module MB released but since the STar on my mechanics laptop wasn't updated, it didn't recognize the part and it gave an error.

I don't know how many months later, I went to my other independent MB specialist here in the Philippines try it out with Vlad's instructions and they got the same error my first mechanic was getting. I insisted it was the correct part number and showed them a screenshot of the EPC online part number was correct and they went back to try it once more. This time they used another laptop with an updated version of Star Diagnostics and low and behold, the module was recognized and my new module is installed!!

Transfer case motor update - DONE!
Transfer case module update - DONE!!
#205642 - in reply to #156120
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Posted 7/12/2012 9:41 AM
Balto
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Location: Scottsdale, AZ
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Re: Transfer Case in Neutral - let's get scientific

BonitaBeast,

Did the problem go away after you replaced just the motor? I know it took you awhile to get the new module to work BUT the time between the new motor and the module working did you have any TC problems?

Thanks.
#205648 - in reply to #156120
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Posted 7/12/2012 9:46 AM
BonitaBeast
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Re: Transfer Case in Neutral - let's get scientific

Balto - 7/12/2012 9:41 PM

BonitaBeast,

Did the problem go away after you replaced just the motor? I know it took you awhile to get the new module to work BUT the time between the new motor and the module working did you have any TC problems?

Thanks.


No TC problems after replacing just the motor. H was always visible on the dash and no slippage of the transfer case into neutral for the last few months. But for piece of mind I really wanted to have the newest TC module installed which is why I forced the issue. I figured there's a reason MB updated the module 4 times.
#205649 - in reply to #205648
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Posted 7/12/2012 10:14 AM
Balto
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Date registered: Mar 2012
Location: Scottsdale, AZ
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Re: Transfer Case in Neutral - let's get scientific

BonitaBeast - 7/12/2012 8:46 AM

Balto - 7/12/2012 9:41 PM

BonitaBeast,

Did the problem go away after you replaced just the motor? I know it took you awhile to get the new module to work BUT the time between the new motor and the module working did you have any TC problems?

Thanks.


No TC problems after replacing just the motor. H was always visible on the dash and no slippage of the transfer case into neutral for the last few months. But for piece of mind I really wanted to have the newest TC module installed which is why I forced the issue. I figured there's a reason MB updated the module 4 times.



I can't blame you at all. Thanks for your time answering my question.
#205651 - in reply to #205649
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Posted 7/12/2012 2:07 PM
oskar
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Date registered: Sep 2006
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Re: Transfer Case in Neutral - let's get scientific


No TC problems after replacing just the motor. H was always visible on the dash and no slippage of the transfer case into neutral for the last few months. But for piece of mind I really wanted to have the newest TC module installed which is why I forced the issue. I figured there's a reason MB updated the module 4 times.


Same here after replacing the motor. Hooked the old motor to a scope and found the signal from the hall unit ( rev counter ) was faulty.
Also took the motor apart, could not find any mechanical damage. Not on the notor nor the gears.

According to a reliable source, the change MB made in the control module was just upping the current limit for the motor.

Oskar
#205658 - in reply to #205651
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