I have a 1991 Mazda MPV . it would not go into four wheel drive. I checked the fuse and found it blown. then i replace it but it blows instantly has it is switched to 4WD. Has any one had this problem and can tell me how the system works. I am worrying it may be some short curcuit in the wiring.

 

Blown fuse I am assuming is the 20A 4WD fuse under the dash? You definetly have a short somewhere. If you can get under the van, look at the rear of the transfer case and you will see a two wire connecter with fairly good size wires in them. One wire is yellow and the other is red. This supplies the power and ground for the change motor. Disconnect wire and then try engaging the 4wd and see if fuse still blows.

 

Thank you for your help, Im sorry i took so long to responde. anyway i found the motor on the transfer case seems that the brushes inside are worn down so the motor is not spinning to change it to four wheel drive, and may have been in a bad position why it blow the fuse. can i get the brushes for the motor or do i have to replace the whole thing?? please let me know
Kwasijam

 

Brushes alone are not available as an individual service part from Mazda. Might check with some electric motor specialty places and they may have an acceptable replacement. Buying a new motor assembly from Mazda will run you $1009.05 and there are only 4 left in the U.S. warehouses. Mazda part #R502-17-9A0D. A good used one would be a good option as well. Checked to see what years would be compatable and looks like same one was used from July, 1 1989 production date up till end of available model in US in 1998.

 

Igot some brushes from a local auto electric store which i modified to fit, i assembled the motor and reconnected. the motor operated when i turn on the van for the first time. but after that i only get the beeps
, and no motor sound. could the gears in side the transfer case be jammed? i really need to get back the 4X4 working, by the way i live in jamaica. so would need to locate a good one b4 i can ship here(used transfer case).
kwasijam

 

Before comdemning the transfer case you might try to remove the motor and see if it will operate normally while not connected to anything. Just have a buddy switch back and forth to 4WD and see if the motor will work then.

 

OK I have reach another stage with the transfer case motor, I found brushes for the motor and repaired it but there is a plastic gear inside the assenbly that has a crack on it, the motor messes directly with it but when ever it rotates and reaches the creack it jams. the gear has some contacts on it to tell the position of the motor. can the gear be found? or what do I do now?