96 won't engage to 4H

I have a 96 Taco with a 2.7, 5spd, and the Manual Lever style Transfer Case and Manual Hubs

When I attempt to shift to 4H (or 4L for that matter), if VERY easily moves the lever to 4H... almost to the point that it pulls it self to 4H if I move just barely outside the 2H location. Feels like nothing is happening with respect to the what the level is doing when going to 4H

At this point, it does not engage the Front wheels. yes, I've double checked that I have the Hubs locked. When "engaged" I can even craw under and freely rotate the front axle and half-shafts.

I'm new to Tacoma's so for those experienced ones, is there any shift linkages or vacuum lines that could be checked prior to pullin the whole case down to check that the Chain(gears?) are all okay within the box? The total lack of feel when shifting to 4H makes me think its not in the transfer case itself. Thanks in advance for any help! Let me know if I can help with any further symptoms.

I've seen some other posts around this... but they spent most of the post arguing whether the original poster had Manual or Push button 4WD.

 

sounds like you hubs are not locked in. if they were then you should not be able to spin the axles.

 

Sound like it is inside the t-case, maybe a linkage issue. It is possible its the chain but could also be the linkage. It should not be 'easy' to move the lever. There should be some resistance to the lever movement.

btw: the first TRD package from Toyota appeared early in the '98 model year, approximately October/November 1997. Do you have an e-locker? I know they were an option before the 'TRD package' was available.

 

Might be the Vacuum Solenoid that engages your 4wd, or the chain in the T-case. I know this couldn't cause it to get into 4H but did you ever change the oil in the T-case? Do you use 4wd often or rarely?

 

Thanks for the replies. I didn't think there would be a vacuum solinoid on a manual shift T-Case, but i'll check it. Are the Linkages / Vacuum Soloid both inside the case, thus requiring me to drop it? OR, can I check some things with it still on the truck?

I just bought the truck, and the previous owner had put factory TRD stickers on the sides. I just recently found out thats false, I just haven't removed it from my profile. I'll admit I didn't fully test the 4wd, lesson learned there.

Also, I purposefully unlocked the hubs to test if Transfer would allow the axle to spin. Took the hubs out of the equation.

 

Solved!!!

Dropped the case and pulled it open.

My going in Theory was that is was something to do with the shift fork or shift rod associated to the engagement of the Chain to drive the front wheels. This is due to its shifting behavior.

My theory was correct, we took the case apart from the back, not the front. (Took off the speedo gear shroud, then took off the entire backplate). From there I could see that the Fork was not broken, but was not where it was supposed to be. The result, there is a very tiny Pressure Pin which locks the fork stop into place. It had bent and fell out... and I found it in the bottom of the case.

Probably a $0.05 part... But I had also had to buy new gasket stuff, new quart of gear oil, and some time. Took about 4 hours total. All in all, happy with the low cost.

Tools needed... Sockets, long extensions, torque wrench, Phillips screwdriver, pry-bar, punches, hammer, Snap-ring pliers, Allen Keys, Jack/Hoist, RTV sealant.

A tip for those attempting to drop the Tranfer... it was REALLY easy to use a cherry picker from inside the cab and bolt it to the case to drop and re-install it. Easier than a jack from below. Be sure to have enough slack in the chain to go all the way up and down.

 

Great to hear Man!

 

Krimson- you mentioned changing the oil in the T-case. How often should the oil be changed? Is changing the oil easy to do? Thanks.

 

Even if you don't use 4x4 much, there is still a drive shaft spinning through it 100% of the time. With that, I can use my Jiffy Lube Technician expertize from 8 years ago to say they recommended it changed every 35,000. It is one of the easiest things on your truck to change and a 96 only holds ~1 quart.

-Remove drain plug
-Drain
-Replace drain plug
-Remove Fill plug
-Fill to fill plug limit
-Replace Fill plug

All are easy access unless you ahve skid plates.