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Old 09-24-2012, 01:28 PM   #1 (permalink)
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Default Front Differential Leaking Air;4x4 light flashing

Question: How do I reseal differential if it is not holding pressure properly? Discussion: 99 Tracker; Flashing 4x4 light - sometimes slow, sometimes fast . I am making an assumption that there is a leak inside the differential based on my observations. Checked system with pressure gage at point in hose where it enters the differential. With gage plugged into line, differential unplugged, system holds good pressure, no leaks, pump actuates and then remains off with proper pressure on gage, 4x4 light remains constant on while shifted in 4wd. When line plugged into differential, 4x4 light flashes, sometimes slow, sometimes fast - pumps continues to pump to maintain pressure. Differential does engage - rotating wheel test, but pump must continuously pump to maintain enough pressure to satisfy. I read the service manual but don't see any instruction on how the pressure circuit inside the differential works or is maintained. The test I haven't run is to add a 3 way and have the gage plugged in with system plugged into the diff but I know I have no leak prior to the diff. Thanks for any help, thoughts, comments. Armylane
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Old 09-24-2012, 05:19 PM   #2 (permalink)
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I know I'm not answering your question, but this gives a good view of what is inside the diff. Also a way of having a perminent fix for you.
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Old 09-24-2012, 07:24 PM   #3 (permalink)
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See...

http://www.suzuki-forums.com/1g-1999...ude-early.html

It's all in there.

The differential's internal bellows / actuator assembly is ruptured (leaking).
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Old 09-24-2012, 07:49 PM   #4 (permalink)
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If the actuator is leaking, you'll probably need to replace it - I know of no one who has repaired one. There are several threads both here and on other Suzuki forums with "work arounds" such as using zip ties to force the clutch into permanent engagement or welding the clutch - you'll need to consider fitting freewheeling hubs if you go that route
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