How To Trouble Shoot 4x4 Actuator

I'm having this same problem right now. What did it end up being?

 

This thread helped me recently with my 4x4 blinky-light issue; when checking my ADD i had to drill out 3 screws; ended up replacing them all with bolts - here's what i used:



I got these at Lowe's - bolt pictured beside upside-down factory screw.

Here's my thread - https://www.tacomaworld.com/threads/flashing-4x4-and-4lo-diagnosis-help-2008-sr5.727677/

tl;dr: Ended up cleaning out the TCase actuator and sanding away some grime and things started working.

 

I’m planning on doing this this weekend, will I need to refill my diff at all? Is there any other things that need to be done that I haven’t read in this thread? Would like to say I’m replacing the diff one not the t case, I’ve got the blindly light. 4wd will engage typically when I first start the truck after it’s been sitting but after that it’s usually blinking light the rest of the day

 

You'll spill some gear oil removing the part - top it off when it's buttoned-up.

 

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Alright, sweet, sounds good!

 

Well… I tried. Got pissed at the last bolt so put it all back together and said I’ll try tomorrow. Any suggestions on that last bolt? Why does it have to be such a terrible design?

 

wobble extension and a u joint socket. Loosen the front diff mounts and it'll pivot down giving better access.

 

Front diff mounts were out entirely, I tried a u joint socket, I don’t have a wobble extension, never heard of that actually, but guess I’ll look into it. I barely gained any extra room dropping the front of the diff down I felt like.

 

Got er done today! New one is installed, gasket maker is now hardening, now we wait! Hopefully I don’t have to take it back apart tomorrow.

 

I’ve been dealing with my 4wd not engaging.I could hear the transfer case actuator running when I turned the switch, but didn’t hear anything in the front diff actuator. After taking apart the actuators and beefing up the connections and testing the motors, the 4wd light was still blinking. Finally gave up and brought it to the stealership to have them diagnose it. They said the transfer detection switches were bad.

 

I think yours may have what mine did - https://www.tacomaworld.com/threads/flashing-4x4-and-4lo-diagnosis-help-2008-sr5.727677/

I had to sand-down corrosion on the inside of the plastic cap for the transfer case actuator.

 

Both of my actuators were clean with no corrosion. I beef’d up the motor terminals and the terminals for the detection switch inside there. After taking the actuators out multiple times with no luck I brought it to the dealership. They’re saying it’s the 4wd-H and 4wd-L detection sensors. I hope that’s it. I wanna change them out myself but don’t want to find out that wasn’t the problem and need to bring it back. If I have them do it, I’m thinking the parts and labor will be under warranty.

 

So the stealership changed out the sensors then called me to say my truck still won’t go into 4wd… the service rep said the mechanic said they need to open my transfer case for $2000, I said hell no, I’m on my way to get the truck. Pretty sure the detection sensors were fine. They had my truck for hours and all they did in that time was screw out a couple sensors. I was able to talk to the technician and input him on the spot. They took off the price of the sensors, but still cost me $400 for nothing. $200 for diagnostic and $200 for labor. And they never confirmed the transfer case actuator worked. They did jump out the detection switch and the front diff actuator and 4wd engaged. So for some reason transfer case rod is not moving back into 4wd position.

 

I wonder if maybe the transfer case actuator gear isn't timed correctly to the shift rod.

 

those Rods are also known to jam up. If disconnect the actuator and see how it feels manually engaging it for binding or rough spots.

 

By manually engaging, do you mean removing the actuator and trying to move the rod back with some Chanel locks or something?

 

yes you should just be able to move by hand.

 

Ok, thanks. I’ll give it a try after work today.

 

Do I need to put the Truck in Neutral, or just leave it in park?