Hi I am new to the forum, and am having a problem with my 200 honda passport. When driving in 4 wheel drive I have NO problem shifting on the fly in and out of 2H to 4H and back, but when driving in 4H at times the 4H-4L shift lever will start to vibrate excessively and will actual "pop out" of 4H and there is a horrible grinding noise. This has happened 3 times. Brought it to the dealer while still under warranty after the first and second time it happened and they could not replicate or diagnose the problem. Now it happened the third time and I brought it to the dealer and it is out of warranty. They want to charge a diagnostic charge. I have not heard if they "found" the problem, just they think thet are going to charge me for something they couldn't diagnose previously. Has any one ever had this problem with the 4 wheel drive. It could be very dangerous. I was lucky enough to have no one right behind me and was able to slow down and pull to the side of the road and disengage 4 wheel. Any help or information would be appreciated.

First thing I would do is get my receipts/work orders for your previous trips to the dealer which didn't result in fixing the problem. I would talk to the service manager and show him that you have been trying to get this problem fixed since before your warranty expired and tell him that you do not expect this to be handled as if your vehicle is not out of warranty. If he tries to tell you that there isn't anything he can do about it inform him that you will be calling Isuzu Customer Service to discuss the dealer's warranty policy regarding this issue as well as the Better Business Bureau.

Now regarding your 4WD problem, does it occur when you are driving straight or turning? Does it occur on dry pavement or when the road is snowy/slippery? Are all of your tires the same size?

it sounds as though one of you fornt tires may be slightly bigger or smaller than the others.
are your tires the same brand and model?

if not, that is the problem. the slipping out to gear is a safety feture, as to not drop the trans/ diff.

These 4wd systems are not for pavement. There is no slippage between the front and rear axles, so the drivetrain will bind up if there is any difference in rotation. Only use 4wd on low traction (gravel/dirt, snow/ice) surfaces.

Yep, check those tires! One or two worn excessively compared to the others will cause the hi-lo range to pop into the dreaded neutral zone :uhoh: . Supposedly this is a safety feature.

G/luck
Joel

Thanks for your suggestions. I have all my paper work lined up, and in order from the previous trips to the dealership. As far as road conditions = snowy roads hence the use of 4 wheel. This is the 5th four wheel drive vehicle that I have owned or use fairly regularly so am very familiar with it applications. As far as tires they are all BF Goodrich All-Terrain TA-KO 245/70 R16 and all the same age so between rotation and mileage they are worn virtually the same. As far as this being a safety feature, it is the worst damn one I have come across, it is down right dangerous. Thanks again.

James, the only other thing I could think of is, clean & grease up the front AND rear driveshaft slip-yokes. These *telescoping* driveshafts and chassis flex are the ONLY things there to help absorb drive-line bind. The driveshafts have to be dropped to do this, but it is easy as they are flanged/bolted at both ends of both shafts.
G/luck
Joel

Experiencing the same exact problem on my 2002 Rodeo. What was the solution?

The solutions are extra matthew46!:grinno: You get about a 50/50 chance of getting an actual follow-up. Check those tires! Just because the receipt says all the tires are the same, doesn't mean they are.

Joel