3rd gen Front Diff Actuator Problems

So couple weeks back out wheeling and crossed a stream about 3ft deep and now i i get a flashing green 4x4 light. Not all the time it comes and goes on its own. When its flashing i cannot engage 4x4 4hi or 4lo nothing happens stays in 2wd. When light is not flashing 4x4 engages fine no issue 4hi 4lo. Read up that 2nd gens had actuator contact point issue's any 3rd gen guys have this issue by the way first and only water crossing that i have done with the truck.

 

I am by no means an expert on this, but my guess is that you got some water in one of the wiring harness connectors to either the 4WD actuator or transfer case, that is completing a circuit when it shouldn't. I would start by pulling all connectors, and making sure contacts are dry and clean.

I seem to remember reading that using dielectric grease on the connectors might help here also, but could be wrong, so google that before proceeding.

Could also drain and refill front diff and t-case fluids, and see if that helps. Lastly pull off the control box covers for both and make sure everything is clean/dry.

 

Dropped mine at dealer today becuase it keeps flashing . Resets in the morning but once I try engaging just stays flashing . Turn off restart same thing ...... gave me loaner 17 mgm OffRoad 40k miles. I’ve never went in water with it either.

 

Doesn't appear to be a water crossing to me, it appears more like you were driving up or down a high country stream.

 

Just a small stream crossing.

 

I'll beat the dead horse. Water is most likely fouling the electrical components inside the ADD. There's a few good videos on YT that show guys taking it apart and fixing it.

This one is a previous gen, but nothing has changed.

https://youtu.be/ZJESG91GbCQ

 

Picked up just now . Warranty

 

open contact point at DL5 pin 5. not the last time that will be seen around here. who's gonna remember?

 

I'm skeptical...
That tech actually busted out the volt meter and troubleshot; that's some unicorn level shit there.

 

from what I've seen here, gotta agree. lol

 

I work for the General Managers construction company. Maybe that had something to do with it and why it was done quick .

 

Okay so took my truck to the dealer to figure it out. Are ready for this? My lift caused the vacuum hose to stretch causing it to unplug itself then dirt and water got inside and is causing it to not engage 4x4. Wait for it! over $2000 to replace actuator due to the fact they have to remove the front diff to get the actuator off! Needless to say i picked my truck up and said no thanks! What is the little black hose doing? Is it some kinda vacum hose? I thought it was a breather. Where does it plug into beside the actuator?

 

Omg are you correct there. We have had 3...3 motors this week at work that were changed when the only problem was a power supply issue. Interviewed a guy for a position we have, asked him if i put a meter down could he tell me what the symbols mean, he said yes, put one down.... Nope

Trouble shooting > guessing

 

Nice catch, didnt even notice the troubleshooting there.
(I dont believe there is a DL5 on the ADD circuit. We will assume he meant DL2 at pin 5 and give it to him.)

I think an open failure of DL2 should have only been apparent in 4wd...

 

I recall it being a breather for the diff and actuator. I recall it running from the actuator to an atmospheric fitting on the upper firewall. If it fell off at the actuator, water spray or deep water could easily enter the diff and the actuator, damaging them, in my opinion.

 

Must be the new guy LOL

 

OP, Let us know how you get it resolved and what is the actual problem vs. What that dealer told you.

By the way this post is extremely helpful and informative.

Also viewed https://www.tacomaworld.com/threads/stupid-4wd-question.622484/ and credit to @Stocklocker for the YouTube link explaining the 4wd system components.

Good luck OP with your fix.

 

If water got into the actuator, at a minimum, you will need to remove it from the front diff and clean it. Look up ADD fixes for 2nd gens on youtube to learn how to remove and reinstall the ADD. Also look up ways to test the functioning of the ADD while it is off to verify it still works once clean. If it isn't functioning correctly, replace it.

 

Is this the same remove and install for the 3rd gen?

 

OP I have a brand new actuator sitting on my shelf...if it comes down to that.
I’d be more than willing to ship it to you.