How To Trouble Shoot 4x4 Actuator

How often do you use it?

 

So I have taking apart my front actuator cleaned and soldered it, put it back together and still have the 4wd light blinking and 4lo not working at all! 4 hi seams to engage sometimes but light still blinks. The only reason I know 4 hi is engaging at random times when I flick the switch is when I drive in circles. Anyone know why this is happening? I want to fix this!

 

The sensors to tell the truck it's in 4wd, 2wd or 4lo are located in the transfer case actuator. Those sensors could be bad or the actuator itself.

 

Replaced my front diff actuator this past weekend and still having the same issues. Truck will shift into 4HI, light will flash even though its in 4HI, switch won't do anything, can't get the truck out of 4HI until after a while it makes a connection and comes out. Any ideas? Tcase?

 

Replaced trans actuator this past weekend and I'm having the same issue as you. I'll be taking apart the transfer case this weekend or next to attempt to find further problems. Changing the oil in the transfer case did seem to help some.

 

Guess i'm joining the Club. Went to switch into 4HI and got the dreaded blinking lights. Both the 4wd green light and orange 4LO lights just flashing. They continue to flash until i shut the truck off and let her sit.

Truck wouldn't switch into anything. Started searching and came across this thread. 18 pages later...i'm going to tackle the ADD fix.

As a backup I ordered a whole new ADD anyway. Got it from RockAuto for $205 with 2-Day Shipping. This truck has been too good to me for the years I've owned it. $200 is nothing for my old girl.

My plan:
- Jack the truck up and perform some quick tests to see whats engaging and whats not while in Drive
- Check and clean all electrical connections
- Provide a couple hammer smacks in well placed areas to see if I can knock something loose
- If nothing changes, remove old ADD
- Install new ADD
- Test system and go from there

When I get the brand new ADD, I plan on opening it up, soldering the 4 weak points and closing her back up with additional sealant, hopefully she it wont need replaced for another 200k! I'm going to take the old one, clean it up and see what can/cant be salvaged for future use, should this issue come back.

Stay tuned!

 

Soooo.....the 4wd just started working when I got home on Tuesday. For kicks, I tried engaging it in my garage with the truck off, and I finally heard all the actuators cycle and move. She went right into 4wd. I verified by doing some donuts in my driveway. WAY MORE GRIP!

Switched in back between 2HI and 4HI a few times and have been doing so since that day. I'm not sure what happened but oh well. We have more bad weather coming, so hopefully it stays working for a bit.

The brand new Actuator arrived yesterday. I'm not sure if i'm going to send it back, on just hold onto it until mine fails. Ill probably hold onto it, open it up and solder everything so that when/if the day comes, i can just install it and go.

 

I would keep it.Did you get a Dorman or OEM?Your problem will come back,I have the same thing going on.In early December during the first cold snap,I started my truck and got the flashing green symbol.Switch was in 2HI.About 3 days later,the light stayed off,and all modes worked perfect.More cold weather and flashing again.About three days ago,temps hit 40 and no light.Tried again and perfect again.4HI to 4LO is also perfect with 0 noise.

My guess is when you first start truck,the ECM checks all modes.If a connection is broken,4WD does not do anything and light flashes.Just like GM with service AWD/4WD message?

 

I'm going to hold onto it. I don't plan on letting the truck go anytime soon, so i'm sure ill need it.

I've been switching into 4HI a lot since all this started happening, seems to working very well, and this truck is a tank in the snow, even on my all season tires.

 

Anyone know if there is a gasket for the actuator? From what I have seen most folks are using form a gasket, but I would like to be able to drive the truck without waiting 24 hours.

 

New member here, but I've been turning to TW for all of my truck needs pretty much since I bought my 2006 taco four years ago.

I had the same issue as a number of posters here... 4x4 wouldn't engage in freezing temperatures (or disengage if it was already in 4x4). I read all of the posts explaining the issue with the front diff actuator, as well as the ones saying that the transfer case actuator could be dirty. The trans case looked to be the less involved repair so I figured that I would start there. Opened it up (just the black plastic part... didn't remove it totally from the t-case), cleaned out the yellow gunk, and re-greased the gear. Put it all back together and test-drove the truck. Not only did it not fix the problem, but it was now stuck in 4-lo. Took everything apart again and repositioned contacts based on diagrams I found. Several tries at this and no luck. I then opened up the actuator, but left it plugged in... turned the key and cycled the selector switch to 4-lo to see if maybe there was a mismatch going on. Reconnected everything, turned the key, and cycled the selector back to 2-hi. The 4-lo went off, but the 4wd light was flashing. Started the truck to test drive and see if this means that it's in 4-hi or 2-hi, but now the truck won't move. What have I done now? I'm really starting to think that I'm in over my head, but hopefully someone can help me out here.

 

The current Aisin part # is

$183 SAT-017 OEM Differential Lock Actuator - Compatible with Select Toyota 4Runner, FJ Cruiser, Tacoma

SAT-017,which fits 2005-2017 Tacomas.I believe the 10 digit numbers are what Toyota uses.Part must have had revisions along the way.I believe the OEM part is made by Aisin?

Rockauto and Amazon are both out of stock,so am looking for one reasonably priced on ebay.

 

bluewlf04
I’m going threw the exact same thing. We had snow down here about a month ago, I tried to put my truck into 4wd and would not. I got to the house, turned truck off went inside got a drink. Came back out got in truck, turned the truck over and was in 4lo but knob was in 2h. Could get it to come out if 4l, drove around the block to see if would disengage, no luck.
Now it’s a 13 with 110,000 Miles and been in the mud once and maybe 4wd ten times. I’ve taken the actuator off and looks brand new. Been reading the posts on here, looks like I have a few more tests to do.
Good luck to you sir.

 

Just took my actuator apart and looks ok even tried it out just hanging from the wire works 100% . My 4wd has been working for the first few min of driving then cutting out after a turn with the usual clunk given when you switch it off , yet the indicator light stays on
Also if u use an indxable ratchet you can access the top bolts without lowering the dif . They are pricy from Mac but worth every penny

 

Getting ready to pull my front add.... What grease should be used in there? Want to replace all of the ~12 year old grease.

 

This has been super useful. Going to attempt the repair this weekend

 

Could someone tell me what this means? There's a Toyota 4x4 official troubleshooting guide?

 

Found a pretty nice video of the actuator removal/solder/reinstall process here... https://www.youtube.com/watch?v=ZJESG91GbCQ

 

So let me understand this after reading most of these posts and comments..

My 4x4 will not engage on my 2008 Tacoma.

The 4x4 light does not light up when switching the dial to 4H. This means the T-Case actuator wiring is faulty?

I no longer hear my front actuator lock. Is this because the rear T-Case actuator isnʻt working?

When the 4x4 light blinks that means the T-Case actuator is working? Which may mean the axle actuator is at fault?

I just replaced both side bearings, rotors and brake pads. A month later and now I have no 4x4...frustrated...

Any suggestions?

 

Iam going through the same BS