Changed my actuator, still hear click/grind sound periodically in 4wd

Hey Guy's,

I have read many of the posts regarding the actuator and how to fix it. Last year I removed it from my 09 TRD and looked inside to find that it was in perfect shape. I did test it and soldered the connectors anyway. Re-installed and still had the same issue. When I put it in 4wd it first would make a loud noise when engaging, then would periodically make a gear grinding sound while driving along. Sometimes when first engaging if I gave'r some gas it would make a big time grinding sound. Eventually I just stopped using 4wd. That being said, I thought it was kind of pointless to have a 4wd (living in an area that gets quite a bit of snow) and not be able to use it. I thought maybe the actuator was just weak, so I replaced it this weekend, and guess what? same issue as before.

What's next??

Thanks,
Kocksan

 

Try engaging without throttle and just coasting while moving. There’s a good chance your clutch hub is worn.

 

Thanks for the response, but isn't a clutch hub on the AC compressor?

 

I would first get under vehicle and have someone engage 4W then disengage a few times. If its not going in smooth try taking off ADD and engage 4w manually a few times. Make sure the shift rail is moving freely. While you are at it drain transfer case and inspect for debris.

 

Do not engage 4WD while "givin'r" That will cause problems...

Does the 4x4 indicator on the dash light up solid after engaging?

And yes I agree with the above, draining the T-case oil and probably the front diff too would probably give you a hint if there was a big issue. Like metal shavings in the oil and on the plug

 

you are correct, just as how there are wheel bearings, crankshaft bearings, idler bearings, there is more than one clutch hub application