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4x4 Problems

27K views 17 replies 6 participants last post by  gee6 
#1 ·
Hello I have a 2003 Kia Sorento and the 4x4 low or auto will not work. I take the control knob and turn it to 4x4 low while transmission is in neutral and nothing on the dash lights up and I tested it in my driveway which has snow and only the rear tires spin . Ive never worked on this , we just got it a month ago. I checked all the fuses in the fuse box under dash and they are all good .
 
#4 ·
Fuses: Fuse 13 in drivers footwell marked TCCS is the primary one that controls transfer case electronics. You have to check them with a meter - looking alone is not always certain with these fuses.
If you just got the vehicle, just have a quick look underneath and be sure you have a connected front propshaft (transfer case to front diff). A previous owner might just have removed a failed one to keep the vehicle going. (But having said that, the dash lights should still work)
 
#5 ·
Fuses are good. I know the shaft is connected underneath. Where is the actuator pump on the 2003 ? I know other years are by battery. ..Mine has nothing there. Does the 03 work different then other years maybe? I need to get this vehicle figured out. I live in Pennsylvania and we get snow here so i really need the 4x4. Just rear wheel drive working now this thing is worthless in snow.
 
#6 ·
If you have switch that says 'auto'/'Low' you have TOD version. No activator pump. TOD uses a multiplate clutch in the transfer case to divert torque to front wheels (TOD=Torque on demand) upto 50%. You need to check the electrical connections to the transfer case (and switch) as previously mentioned. Is there anything else that is not working? Some of the systems are interlinked in non-intuitive ways .......... (blown rear-wiper fuse can disable the a/c system and other stuff for example).
 
#7 ·
Hi. I have exactly the same problem with my sorento. I have 2.5 TDi with TOD. When i turn the switch to 4x4 low nothing happens. No light or noise. Front wheels also not working. I have replaced clutch pack and oil in transfer case. No change. Then i replaced transfer case module. Again no change. Only rear wheels are spinning. Front is never engaging.
There are no faults on cars computer. Electrician has checked all the wires. All turned out ok. Does anyone know what else to check.
 
#8 · (Edited)
When the 'lectrician checked the wiring did he actually verify if the shift motor in the transfer case was operating?

ps Some fault diagnosis is restricted to the Kia specific diagnostics port in the engine bay and will not show up on the OBDII port.

pps Do the dash warning lamps for 4x4 etc come on when turning on the ignition? Any flashing?
 
#9 ·
Thanks for the quick reply. Yes the actuator motor is working when given power from other source then car. When ignition is turned, all the lights are illiminated in the dash. There are no blinking lights or fault lights when the car is running. Basicly car is running fine. Just no power for front wheels.
 
#12 ·
After raising it up on lift we fpund out the transfer case is working. However as soon as pressure is applied to tires or light braking it kicks out. We drained transfer case , fluid was burnt. Put new fluids in and still acting the same. Clutch packs have to be bad. For it to disengage as soon as some weight is on tires or lightly putting brake on . These Tod cases are hard to find. How hard would it be to just replace clutch packs?
 
#13 ·
If you search around you will find the Kia TSB detailing clutch replacement (with part nos). Just make sure you put the correct fluid in the transfer case (Clue: It is not simply 'atf' or 'dexron III').
 
#15 ·
So im assuming the only fluid that can be used in it is KIA P/N: UB080 CH031 ? Is there something from a autopart store that can be used ? Like I said the manual states dex 111 but ive heard this is not to be used now.
Also for those who are having the Tod clutches going bad , here is the link to the instructions on part numbers and how to change out clutch packs

http://australiancar.reviews/_pdfs/Kia_Sorento_BL_TSB022.pdf
 
#16 ·
Fluid: Never tried it, but I'm told you can use some friction modifer if you have refilled with dexron III. It provides sufficient slip to stop the clutches being destroyed. Can be obtained on line or from Jeep for example. (again, so I have heard). Kia UK also changed the service interval on the t-case to 20000 miles or 2 years, (from 40k/4yrs), but North america always seems to have shorter service intervals anyway.
 
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