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Problem with G500 any advice
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Posted 5/16/2007 2:30 PM
Marx
Veteran




Date registered: May 2006
Location: Pretoria South Africa
Vehicle(s): 230 GE /1989, 300 GE/1984,300GD/1980,280GE/1984
Posts: 127
100
Problem with G500 any advice

Problem with a G500

There was a failure on the front diff lock of a G500 (2001 model) .The diff lock was mot engaging at all ,the orange light on –red light not coming on indicating the lock is in
Found fault (faulty relay)
Great performance after in a 4x4 challenge, took the car through its paces no problem (full day challenge driving)
After the challenge was completed started the car – None of the diff lock lights on the centre console came on if you pressed the lock buttons.

Tested vacuum pump separately straight from the battery /vacuum pump works ok
No fuses blown, but still cannot get diff locks to engage, no diff lock lights on display panel comes on when you push them

Has anyone had a similar problem?
Any advice?
#74602
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Posted 5/16/2007 2:34 PM
KERR

Date registered: Dec 1899
Location:
Vehicle(s):
Re: Problem with G500 any advice

No clue, is that you jumping in the picture?

#74604 - in reply to #74602
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Posted 5/16/2007 2:38 PM
Marx
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Date registered: May 2006
Location: Pretoria South Africa
Vehicle(s): 230 GE /1989, 300 GE/1984,300GD/1980,280GE/1984
Posts: 127
100
RE: Problem with G500 any advice

Yes that's me in a 1984 ,460 280 ge I have recently been forced to convert it into a cabrio (my son rolled it )




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#74606 - in reply to #74602
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Posted 5/16/2007 4:00 PM
Maxwell Smart

Date registered: Dec 1899
Location:
Vehicle(s):
Re: Problem with G500 any advice

It looks like its got (had) a double sunroof?

Don't really know a whole lot about diff locks but I do know I had problems once where it just wouldn't lock in (red light) even though the orange was on. I took it to a dirt road and did a lot of hard zig zags and eventually they all engaged. But it took some effort... worked fine after that.
#74616 - in reply to #74602
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Posted 5/16/2007 4:52 PM
DUTCH
Administrator Doppelgänger




Date registered: Apr 2006
Location: US, GA, Atlanta
Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter
Posts: 9963
5000
RE: Problem with G500 any advice

Marx - 5/16/2007 2:30 PM

Problem with a G500

There was a failure on the front diff lock of a G500 (2001 model) .The diff lock was mot engaging at all ,the orange light on –red light not coming on indicating the lock is in
Found fault (faulty relay)
Great performance after in a 4x4 challenge, took the car through its paces no problem (full day challenge driving)
After the challenge was completed started the car – None of the diff lock lights on the centre console came on if you pressed the lock buttons.

Tested vacuum pump separately straight from the battery /vacuum pump works ok
No fuses blown, but still cannot get diff locks to engage, no diff lock lights on display panel comes on when you push them

Has anyone had a similar problem?
Any advice?


Sounds like you have a fuse or a relay problem. Here's a schematic of the system. Maybe this will help; but if you're not getting lights of any kind, you must not be getting any power to the switches.





(DiffLocks.jpg)



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Attachments DiffLocks.jpg (108KB - 2 downloads)
#74625 - in reply to #74602
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Posted 5/17/2007 8:59 PM
ewalberg
Expert




Date registered: Apr 2006
Location: Past: San Francisco. Present: Germany
Vehicle(s): 2000 g500
Posts: 1887
1000
Re: Problem with G500 any advice

yeah what dutch said. The switch box should always light to tell you that it knows you've pushed a button. AlanMcR has pulle the switch boxes apart and i believe it's got a redundant check to make sure you've pushed it and the light is part of that. That said, the rear doesn't get power till the front pushed and verified as such, and the front doesn't get power till the center button has been pushed, but looks like the box doesn't know the center is getting pushed... if the box is getting power then it's the switch box. I think on benzworld i posted the wiring diagram for the lockers and switch box.

Side note from memory... pin 7 get grounded when the sensors in the axle or t-case read something is locked... if that's grounded abs never comes on... same pin is used and gets grounded on the older trucks when the ABS kill switch is activated. The wiring harness is (in fact still) in your dash ready to hook up a factory ABS kill switch if you want it... you just need to make the hole in the trim for it. I found the harness during some stereo work.
#74794 - in reply to #74602
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Posted 5/18/2007 5:41 AM
Marx
Veteran




Date registered: May 2006
Location: Pretoria South Africa
Vehicle(s): 230 GE /1989, 300 GE/1984,300GD/1980,280GE/1984
Posts: 127
100
RE: Problem with G500 any advice

Thank you for everyone's advice ,it seems to be the diff control system needs to be replaced
The part nr I have is MA 463 545 0332
It's 2001 G 500
chassis : nr 4632412x123045

But it seems the part is not available from local dealer









(g500 b.jpg)



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#74844 - in reply to #74602
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Posted 5/18/2007 3:55 PM
AlanMcR
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Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
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RE: Problem with G500 any advice

Marx - 5/18/2007 2:41 AM

Thank you for everyone's advice ,it seems to be the diff control system needs to be replaced
The part nr I have is MA 463 545 0332
It's 2001 G 500
chassis : nr 4632412x123045

But it seems the part is not available from local dealer





Test the circuits that go to the control box before buying anything. The control box is built with very sturdy old time electronics (no microprocessor). It would be very hard to kill it. Also, the various internal circuits are largely independant. Failure of the entire unit is pretty unlikely.





(DiffLockCircuit.jpg)



(DiffLockLegend.jpg)



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Attachments DiffLockCircuit.jpg (238KB - 1 downloads)
Attachments DiffLockLegend.jpg (69KB - 1 downloads)
#74888 - in reply to #74844
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Posted 5/21/2007 8:51 AM
Marx
Veteran




Date registered: May 2006
Location: Pretoria South Africa
Vehicle(s): 230 GE /1989, 300 GE/1984,300GD/1980,280GE/1984
Posts: 127
100
RE: Problem with G500 any advice

Thank you again for above advise ,I am taking all of the above to the people working on the G 500 ,maybe they can resolve this . I will keep you posted if they do
I am still worried that it might be the part it self and I have phoned everyone I know for the part ,it seems there are none in stock ,does anyone know where I can try to get a second hand one ?
#75123 - in reply to #74602
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