4x4 Issues, Front diff actuator or t-case actuator?

With that said, the truck is now drivable and I think in 2 wheel drive. I would like to take off the t-case actuator again this weekend and do some tests on it. Does anyone know how to test the motor while it is off the truck? I heard of someone connecting it straight to the battery to see if it would actually run. Is this the proper way to test to see if it works? Other then that, I read there could be some issues getting the actuator aligned back to the t-case. I attached 2 pictures of the actuator taken apart, let me know what you all think.

 

I stole this from another page

Actually you may want to just read the whole thing.

http://www.tacomaworld.com/forum/2nd-gen-tacomas/353584-transfer-actuator.html

 

Good call. I guess they are 12mm, my bad.

 

Well tore apart both actuators this weekend to find out that they were both in working order and found the problem to be a small gear inside the front actuator assembly. See attached image. We notice after testing that because 3~4 of the teeth were broken off it would not turn the larger gear which engages the front. Since it was just turning in there it never engaged the front and the computer never told the transfer-case it was ready for 4WD. Actually all quite interesting once we got it figured out. With that said, since they don't sell the gear separate I think I'm going to try and 3D print it since the only other option would be purchasing the entire front actuator assembly. Ill let you guys know how it turns out and if it works!

Also attached is an image if anyone gets themselves into trouble by taking the entire t-case actuator apart like I did and have no idea how to get it back together. Just a heads up, if the gears do not go back together correctly your 4 wheel drive will be all off. Make sure to line up the metal contacts as shown with the arrows. Hopefully that helps everyone that was as confused as I was.

 

Hey guys, I wanted to let you all know the 3D printed gear was a success! The install went perfect and has been working for a little over a week. Going this route also saved me a ton of money not having to buy a whole new actuator! If anyone else has this gear go out I have the files uploaded on a site where you can get them printed for $15. Feel free to hit me up. Thanks again for everyone's help!

 

Interesting. I wonder how long the plastic gear will last if the steel one broke?

 

The original was nylon plastic material. All the gear in the actuators were. We tested the original vs. the 3D printed part for hardness and strength and both came out to be fairly similar.

 

Very cool, good job locating the issue and coming up with an economical solution! Could you update with a report on more longer term durability in a few months? I'm curious as to the durability in varying temperatures, etc.

 

I didn't know that, pretty neat that you can replicate it so easily. I wonder how common the broken gear thing is? Most people just replace the whole assembly without investigating why the old one is kaput.

 

My Son was tapping on Tcase actuator and broke nipple on vaccum hose, will i have to buy WHOLE thing?? $1200.00 T case actuator sounds like it is operating but front one has no sound when turning switch.. it is stuck in 4 high,, it will go to 4 low and back to high but wont go to 2 hi. I am lost!!!!

 

That's just a vent hose. Get some quicksteel and put the nipple back on there. You can manually shift it into 2HI. Push the shift shaft (the thing the T-case actuator is hooked on to) all the way in. One click out is 4hi, two clicks out is 4lo. You can repair both actuators. Read through this thread and you will be an expert on how to do so.

 

i have a 05 tacoma that has been giving me hell it started out not shifting in to 4 wheel drive .replaced the front actuator still no 4 wheel drive replaced the transfer case actuator now have 4 lo but no high the mechanic thinks its a timing issue with the transfer case motor any one how to check the timing or could it be the sensors

 

this exact thing happened to me tonight in my 1st gen (although my 4wd light won't come on at all). OP are you still out there? if I need a 3D printed part can you help me?

 

THIS POST!! - Got me up and running today, THANK YOU!! I searched for DAYS....

I couldn't find an "alignment" post/topic.

I'll update my NEWB post for clarity soon because everyone has 4WD issues, but MANY don't post the result, the fix, actual repair when done...

 

2019 checking in, time to repair my 4WD hahaha!

 

Hey all,
So I already took apart and soldered my 4wd ADD actuator. The 4wd light is still blinking, but oddly now I can switch back and forth between 2 and 4wd, BUT only when starting the car. If I turn the knob while the car is running nothing happens. But if I turn off the car, and turn the key as to not start the car, I can turn the knob, start the car and I'll be in the selected drive every time.

I have dug around several posts for the last two weeks and I haven't found any case similar. Does anyone know whats going on or have a link to a post i possibly missed?

 

Sounds basic but have you tried removing the battery cables and resetting the computer?

 

Try letting it sit without touching the battery for a good bit

 

Yeah didn't work, I disconnected the battery for a little over 24 hours and no luck, still blinking...