Ok let me make this clear.
The moisture is getting in where the 2 parts of the solenoid are fused together.
If you take one and look close under the upper hose nipple you will see that there is a small gap. Also when I pulled it apart I found moisture inside the valve. Maybe it sucks it back from the vent? The rust i found was at the top of the solenoid inside where the two terminal connect to 1, the copper wire and where the 2nd terminal connects to the steel outer case of the solenoid (covered in plastic so you do not see it) This steel shell also had rust on it at the same point near the seam. I took a ohm meter to it and from the terminal to the copper coil no connection.
All this solenoid is,, a steel sleeve wraped with copper wire. Inside the sleeve is a spring loaded needle with 2 seats. when powered up it closes and lets vacumm pull the IWE's in to release. when no power it blocks the port and you get 4wd.
Mine was rusted at the terminals inside the solenoid so it was losing connection off and on. I would hear a clicking from the needle going up and down at a fast rate.
Last edited by 4406brl; 03-05-2010 at 05:17 PM.
Reason: more info