4x4 Actuators Gen 1

I have an '02 TRD with 237,000 miles on it. No oil leaks! I want to add on to a thread I read in the Gen 2 area on trouble shooting 4x4 actuators.

https://www.tacomaworld.com/threads/how-to-trouble-shoot-4x4-actuator.263525/

My truck wouldn't come out of 4x4. The dealership wanted to replace my Transfer Case Shift Actuator Assembly, the part alone is $1100 and they have to open the transfer case to install it. So not a cheap repair. I noticed the vacuum line going into the actuator was cracked so I took off the cover to look inside. I did all of this without removing the Actuator Assembly from the transfer case.



I think it is safe to say I had some corrosion lurking in the actuator. Impressively the actuator and 4x4 works after a quick rebuild. I cleaned everything:



These two pictures are still dirty, I didn't stop to take pictures, but I cleaned them and reassembled them too...



Before I put the electrical portion back on the mechanical portion (I point this out because I did not remove the TC Actuator assembly from the truck) I applied a generous amount of dialectric grease. You can kind of see it in this photo:

 

Out of curiosity I looked at my front Differential Actuator (ADD) and was pleasantly surprised. I did remove the ADD from the vehicle. I had to take the electrical portion off of the mechanical portion and remove them as separate pieces in order to get them past the rack and pinion system. Had I known that before I started I would've left the mechanical piece bolted to the differential.



I cleaned them up...



And applied some dielectric grease before installing the assembly back on the differential.

 

I think you just made a 1000$ economy. congratulations. the future is in your hand.

 

So I’ve seen this mentioned with 2 different methods to get the actuator out. One is to loosen the front diff mounts and drop it down. The other is as you mentioned to dissasemble the actuator. Any way easier than the other? Any issues with the dissasemble method? Is it difficult I get back together?

 

You need to drop the front dif to get the front actuator off and out.
At least on 2004.

 

The 95s have vacuum diaphram only. W/H connection is just for the light. I changed one of them without removing anything or dis-assembling it, but it took me a solid 20-30 mins of twisting and turning it to get it out, and then same back in. A real PITA!

 

The 2001-2004 don’t have any vacuum right? There all electric

 

Not on my truck (2003, manual transmission). Whole unit came out in one piece…no dicking around with the rack or the diff. I think there is less clearance with the automatic.

 

Less clearance with the automatic but I did the same as you. Had to jimmy it out

 

That's my understanding.

From reading on here, only the first few years had vacuum.

 

I didn’t have to. Gotta jimmy it

 

The electronically actuated T cases are a pain to find since the part number is the same as the standard type. Glad to know about this in case mine ever goes out.