92X 4x4 won,t erratic engagement tried search & DRBob ideas

[sholzee]

Symptoms press 4x4 buttom clicking from rear controller sometimes 4x4 engages sometimes not usually never on first try but repeated pushes on the button. 4x4 low has not worked in about 3 years but 4x4 high would engage now its harder to get 4x4 high. Front hubs are both in good working condition.Tried DrBobs ideas the motor armature and brushes looked almost like new cleaned them anyway. Could not get the safety torx off the switch cover broke the head off one in the process of removal and stopped there for fear of breaking them all off.

1) Can dirty switches be causing my problem ?

2) If I break all the switch screws whats the best repair process ? drill out remaining thread ?

3) Never have I seen the LED on the controller light, what does the LED and white reset switch do ?

 

[Opera House]

Not always the brushes

I recently rebuilt the one on my 92. This was the third time (about every 2 years). This time I decided to run in my motor on a bench power supply by removing the switch gear that has a stop on it. The motor drew over 4 amps and the supply went into shutdown. This was after my normal application of lubricant. Worked in some really thin oil and it went down to 1 1/2 amps. Pulled it apart again with more bearing cleaning. After a little more "run in" the current was less than 3/4 amp. You should be able to run the motor off 12V with a brake lamp in series with the power and it should easily start in both directions. If it doesn't the motor is binding.

Moral of the story is the electronics is PWM and unable to supply more than 1 amp. The motor does not run on a full 12V (way too fast) and should be able to operate on 6V easily. When the motor draws too much the electronics goes into shutdown.