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Thread: Hilux Surf kzn185 - Looking for proper Mechanics/workshop

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    Default Hilux Surf kzn185 - Looking for proper Mechanics/workshop

    Hi Guys,

    I recently got a Hilux Surf KZN185, with 1kzTE, It does not engage front wheels, produces a gear slipping loud continuous noise if 4wd button(4H without Lock) is pressed. It has been diagnosed as a mechanical failure in the transfer case. The vehicle runs fine in 2H , In 4H-L mode, it does not make that noise, but still does not engage front wheels, no front wheels in 4L as well.

    I want to know about experienced Mechanic/workshop who are experts with Toyota Jeeps & SUVs, and sources who have Kabli transfer cases in RWP.

    Help will be appreciated.
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Quote Originally Posted by minex View Post
    Hi Guys,

    I recently got a Hilux Surf KZN185, with 1kzTE, It does not engage front wheels, produces a gear slipping loud continuous noise if 4wd button(4H without Lock) is pressed. It has been diagnosed as a mechanical failure in the transfer case. The vehicle runs fine in 2H , In 4H-L mode, it does not make that noise, but still does not engage front wheels, no front wheels in 4L as well.

    I want to know about experienced Mechanic/workshop who are experts with Toyota Jeeps & SUVs, and sources who have Kabli transfer cases in RWP.

    Help will be appreciated.
    Sir this might be an electrical issue with gear n button u r pressing please have it checked first rather than going directly to transfer case.
    If 4x4 is not engaging at any time than high probability is mechanical failure if it happens on certain electrical buttons than check the electricals first and also check vacuum pipes are connected properly

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    First diagnose the problem than i will share with u a number from whom u can purchase any part at a good price

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    You can take it to Farooq Awan 0333 5207251 at City saddar road

    Quote Originally Posted by minex View Post
    Hi Guys,

    I recently got a Hilux Surf KZN185, with 1kzTE, It does not engage front wheels, produces a gear slipping loud continuous noise if 4wd button(4H without Lock) is pressed. It has been diagnosed as a mechanical failure in the transfer case. The vehicle runs fine in 2H , In 4H-L mode, it does not make that noise, but still does not engage front wheels, no front wheels in 4L as well.

    I want to know about experienced Mechanic/workshop who are experts with Toyota Jeeps & SUVs, and sources who have Kabli transfer cases in RWP.

    Help will be appreciated.
    75% of earth is covered by water... the rest by Jeep
    www.brokenknucklegarage.com

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    @mwanwar
    We have done a few tests, and the problem is not electrical, the sound is a continuous slippage or grinding or the gear teeth,,, very very harsh indeed. The electrical button is 4H (without Locking), it sometime happens with Locked center diff as well.
    @akifjanjua
    Thanks,
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Quote Originally Posted by akifjanjua View Post
    You can take it to Farooq Awan 0333 5207251 at City saddar road
    Directions please.
    Qaiser Pal,I have not failed.But found 1 of 10,000 ways which doesn't work.....Toyota driver "I couldn't repair my brakes,so i made my horn louder"..When i was born i was so surprised that i didn't talked to one and half year..since light travel faster then sound,people appear bright until you hear them speak..If u can't convince them,confuse them

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    Please call the guy on his cell for guidance.. the shop is located on the bank of nullah leh indicated by the red arrow... while coming from Saddar/gawalmandi side you turn right just after crossing the Leh bridge on city saddar road.

    Hilux Surf  kzn185  Looking for proper Mechanicsworkshop -1554762
    75% of earth is covered by water... the rest by Jeep
    www.brokenknucklegarage.com

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    @akifjanjua

    Bundle of thanks..Also please tell a suitable time to take our 'BIG' vehicles in that immensely congested area with traffic jams all the time.., Last time I went there, it took me 1 hour just to cross city saddar road.not to mentioned the scratches my rig received via various donkey-carts and carts.
    Qaiser Pal,I have not failed.But found 1 of 10,000 ways which doesn't work.....Toyota driver "I couldn't repair my brakes,so i made my horn louder"..When i was born i was so surprised that i didn't talked to one and half year..since light travel faster then sound,people appear bright until you hear them speak..If u can't convince them,confuse them

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    Oh i can understand .. Call farooq to setup time.. he is in process of setting new place on the road parallel to railway station.. out of the congestion zone just near that area on road parallel to the railway line... just ask for the place
    75% of earth is covered by water... the rest by Jeep
    www.brokenknucklegarage.com

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    Hi Guys,

    Ok so the problem is solved, but as there is not too much information is available on the internet, and some info is misleading, i will share my experience here.


    Original Issue : Chain Slipping sound fron Transfer case only in 4H mode
    Other symptoms : No Power to Front wheel in 4H-L or 4LL mode. But no slipping sound from T-case


    Diagnosis: Mechanical Failure of Transfer Case.

    Solution: Replacement of Transfer Case (kabli) expense of 16k to 18k pak rupees

    Technicalities: Try to find a Transfer Case with original motor (actuator) attached to it, otherwise haggle and bring the price down to 14 or 15 k. You will still need a motor, taken off another T-case or your original t-case(if the motor was fine.)

    Complication: This is the most complicated issue, if you dont get the original motor (never taken off) of the T-case you bought, then you wont get 4x4 function, and your 4wd ecu will detect that the motor is not calibrated and your 4wd indication lights will start blinking.

    I have searched high and low on internet forums, some even say that this setup is useless and you need a complete t-case with original motor, some give a slight idea about adjusting the calibration but no method or steps.

    However It is possible to calibrate an actuator motor with the new T-case, and Hameed electrician and his guys near Gawal Mandi did it for me, charged me 3000 for it, but they normally charge anywhere between 4 to 7k for this Job. It can take between 1 hour and 3 hours.. (they say it can even take upto 12 hours) but if there is no other problem in the car I dont think it will take more than 2 hours or so.

    Here are the directions , near Marir chowk, Muree Road,
    Hilux Surf  kzn185  Looking for proper Mechanicsworkshop -1559970
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Glad that its fixed.. learning begins

    the adjustment is not mentioned in any FSM.. its a hit and trial procedure.. and works
    75% of earth is covered by water... the rest by Jeep
    www.brokenknucklegarage.com

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    yea, true, but not many electricians know about this. and can mislead to change the whole T-case just for the motor.
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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    Yes.. but the ones who routinely work on 4x4s know it.
    75% of earth is covered by water... the rest by Jeep
    www.brokenknucklegarage.com

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    actually i ended up with this problem because the motor on my kabli tcase had a broken housing, we found that later on, the parts guy supplied another kabli motor, and did not have any other complete t-case with the same 6 pin original motor fitted. I got a good deal and he will let me keep my old motor which apparently looks to be working fine. The parts are in a very good condition, so I am not too worried now that the problem is resolved.
    Do the environment a favour, Use less airconditioning .. and please walk to the shop to get a pack of cigarretes..its only a 3 min walk..

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