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W163 ML320 Stuck in Low Range

6.4K views 24 replies 6 participants last post by  joco1555  
#1 ·
My truck is stuck in low range (low range light is on). It drives like a bus and won't shift. Occasionally, the low range light turns off by itself when cruising for ~3 seconds and it can shift again, only to turn back on right after.

These are my codes:

ETC
041:

"[One or more messages from control unit N78 (Transfer case control module) are intermittently not available on the CAN bus or the transfer case position is position is intermittently implausible.] or [One or more messages from control unit N78(Transfer case control module) are not available on the CAN bus or the transfer case position is implausible.]
DTC Status: Resistance too low"

137:

"One or more messages from control unit N78 (Transfer case control module) are intermittently not available on the CAN bus.
DTC Status: Resistance too high"

AAM
B1040-003:

"CAN BUS: communication control: N78(distributor drive control module)
DTC Status: Stored"

I have tried clearing the codes, but they still remain. "Low Range" Light is on 99% of the time. I read somewhere that I must replace the transfer case motor (as they are prone to fail). Is this correct? If so, is there an updated transfer case motor (where they corrected this flaw and what is the part number)? Should I get a genuine MB part or an aftermarket like Dorman? When installed, do I have to clear the codes again or is there just gonna be no "low range" light?

Thanks in advance.
 
#7 ·
When you say that do you mean just the light goes off or it physically disengages for 3 seconds?

If it disengages low then your motor is working, and Witek thinking about the module is on track. Have you left the sunroof open during a downpour?
 
#11 ·
I am on my phone so don’t have access to the wiring diagrams. But if there is a relay involved here I wonder is it sticking shut? If there is try replacing/ swapping see if problem persists. Very inexpensive check.
 
#17 · (Edited)
I had the same issue! I've never used low range, but one day when I started it, it was in low range.. It would set itself back randomly after a few seconds to a few minutes, but would kick the car in and out of low range randomly while I was driving.

I had to replace the Transfer Case Shift Motor (1635400888). I got it from eBay for ~$50 and replaced it myself under the car with minimal effort (like 5 bolts). To my knowledge, all that motor's job is to flip a hardware switch to make the car go back and forth from low range. The motors can go bad, loose, or get stuck. Mine was just loose I guess. I didn't have any codes for it on OBD, but sounds like yours is related. It's low cost and low effort to swap it out, I'd give it a shot. I used this video

No issues since
 
#18 ·
I had the same issue! I've never used low range, but one day when I started it, it was in low range.. It would set itself back randomly after a few seconds to a few minutes, but would kick the car in and out of low range randomly while I was driving.

I had to replace the Transfer Case Shift Motor (1635400888). I got it from eBay for ~$50 and replaced it myself under the car with minimal effort (like 5 bolts). To my knowledge, all that motor's job is to flip a hardware switch to make the car go back and forth from low range. The motors can go bad, loose, or get stuck. Mine was just loose I guess. I didn't have any codes for it on OBD, but sounds like yours is related. It's low cost and low effort to swap it out, I'd give it a shot. I used this video

No issues since
Ok I’m going to give it a try. I did unplug the tc motor because I read somewhere that it could be it. I cleaned it too see if any changes but I’m better off just getting a new one that way I can rule it out. Thank you hoping that’s the fix.
 
#19 ·
just chiming incase it helps anyone.

in the original post, what caught my attention is the "transfer case position is implausible " bit
so in this case,
1) I would probably clean the connectors/wiring, I assume one of these would carry the signal to tell if the position is low range engaged or not (if you have a scanner, it might be possible to see if live data can read the position, I have to try this myself as well)
2) failing that (its not a wiring/connectivity issue), then I'd look into exchanging the motor itself (assuming the transfer case position sensor in there somewhere is faulty) - but my best bet is #1 above especially if low range is not switched at all (if you have the time you can probably open up the motor to see what else could be wrong with it)

my truck's low range occasionally gets stuck and in some cases a light tap using a rubber mallet on the motor does the trick, ive read someone drilling a little hole and spraying some lubricant to temp fix this (reseal back after)

anyway, good luck, looking forward to some confirming what fixed the issue (for future reference of all readers :) including me, thank you)
I note that from @joco1555 its the replacement of the motor itself that fixed it