Mitsubishi Repair Problems? Ask a Mechanic for Answers ASAP
Hi Don,This is very common behavior and is nearly always related to either a bad free wheel clutch solenoid pack or a vacuum hose issue like you are familiar with.
You are going to want to approach this similar to you did before when the solenoid failed.... first make sure ALL of your vacuum lines are intact, none damaged or disconnected etc and that includes down on the front axle and around the engine intake etc.If all look good, I would take a hand vacuum pump and apply it to the off side of the actuator on the front axle and draw the actuator out to fully engage 2WD. Make sure it is secure (zip tie it up etc) and confirm the grind is gone. If the grind is still present there is likely damage to the actuator or fork etc in the differential. More than likely the grind will be gone.At that point we know there is a vacuum supply issue to the actuator preventing it from fully engaging 2WD.From there you would want to pull the solenoid pack again, test resistance on both coils, and check with a hand vacuum pump for vacuum retention on both solenoids... if either solenoid holds vacuum regardless of voltage being applied/removed or leaks vacuum (even a tiny bit) regardless of voltage being applied/removed, you will be in for another free wheel solenoid pack.I know it was just replaced 2 years ago, but if the vacuum lines are all intact it is still the most likely culprit... I've seen them fail earlier than 2 years old as well. Do the checks though and it will get you to your issue.
Yes, the passenger side should draw away from the differential and the driver side toward it.I've seen one actuator fail. Ever. The solenoids are usually it.When I say tie it up, I mean secure the vacuum pump while it is holding vacuum so you can test drive it.