4WD problems, Round two

Could it be that the clutch itself is not fully disengaging when the clutch pedal is fully depressed. So it needs to be in neutral via the shifter for 4lo to engage? Glad it works with those steps, though!

 

Nah, the clutch is fully disengaged FAR before the switch at the bottom.

I've been planning to bypass that dumb switch for a while- but after all this maybe not so much.

In the winter, it's nice to reach in and start the truck without getting in, so it can run while I clear off the snow. Can't do that with the clutch safety switch... A few times I used the button to bypass it, but once it got cold enough the switch stopped working. I do miss that about my '99, and every other stick shift I've had over the years.

 

Yea basically it's the can't shift now, try again later alarm.

Once you learn how it reacts and what to do it's no big deal but yea it could be better.

I don't think so due to how the system and actuators are designed, the actuators both have a "wait" mechanism which is essentially a spring that allows the actuator motor to move into position and when the gears line up the spring pushes the shift fork into place.
The limit switches (TL1, TL2, TL3, DL1, & DL2) tell the 4wd ECU the position of the actuators and the detection switches (4WD, L4, & ADD) tell it the mechanical position of the Transfer Case and ADD.

I had that exact problem with my Clutch Start Cancel Switch, take it apart and clean the heavy grease they use off the contacts. Since I did that mine has worked flawlessly.
https://www.tacomaworld.com/threads/clutch-start-cancel-doesnt-work-in-cold-weather.752554/

 

Excellent! Glad you got it figured out and thanks for circling back and letting us know the fix.

 

Ah ok! Very interesting, thanks for taking the time to explain that.

 

I think so at least
Still need to do the hot-test, the holiday today completely threw my schedule off... but it's looking promising.
Looping back to follow up is the least I could do, the knowledgeable experts on this site are better than any mechanic I could possibly afford to hire- because the information is very model specific!
Most any problems I could have with this truck, other members here have had and solved before on several occasions.

Now I just need to find the time to finish up some outstanding projects on the truck so I can learn enough to share with others.
If there's one thing I miss most about my '99, it was how well I knew it... and how little work it demanded of me to do exactly what it was designed to do.

 

Just a couple of things to add: One that is very important is to never turn the truck off when the system is trying to complete a shift into or out of 4WD. It can go into "confused/unknown" mode when it loses power in the middle of a shift where it doesn't know what to do and basically "gives" up. I know this seems to be the only way to correct your particular issue at present, but thought I would mention it. There are manual fixes for this when it happens, and one involves moving the front fork manually to get on your way again. I try to never willfully shift into 4L in the field unless absolutely necessary, because where I go is 5+ miles off the main roads. Not a distance I ever want to travel in 4L because it decides to be cranky. I engage 4H once a month or when we get rain or snow, but I only engage 4L in my driveway. It's always drama when I do it. It rarely engages the first time without moving a little forward or backwards or moving the dial again.

 

Last time I wanted 4L and couldn't have it, I was knowingly going bumper deep in water/mud up in the "North Maine Woods" compound - we're going back in less than a month. That was on the way in, on the way out it was over the bumper... I should probably check my breathers and change fluids after this time

I did some damage to my clutch last time being unable to get into low gear, but we got through. I wound up having to winch out at the end, but that was my fault going too close to the edge of the "road" and slipping off in the rear. Fortunately I was following a friend in an FJ who had gotten through before that happened. This year he has a winch too

Looking forward to having low gear this time around. Hopefully it isn't so wet.

 

I have found over time that the more often I cycle the system to exercise 4L, the more smoothly transition is back and forth. Even the signature "clunk" gets quieter. 2H to 4H and back is always drama free: unless you shut off the truck while it's still working on it... Doesn't like it at all. (Don't ask me how I know.)