How To Trouble Shoot 4x4 Actuator

@FrustrationFabTaco

 

My actuator came in yesterday. I ordered it from a dealer in Massachusetts. I got it for $280 with second day air. Local dealer wanted $435. I was moving the vehicles around this morning to set up to do the work, and I threw it in four hi and WAMO, it worked! IDK what the hell is going on. Four hi and low are working. I'm going to wait for the time being on swapping out the part. I'll keep you posted.
Thanks

 

UPDATE: Since it's sunny and 70 degrees, I installed the actuator today. All went well and for the first time I got to put the truck in 4 lo with the locking rear working. I'm glad that I got a chance to put it on before the weather changes and its freezing cold out.

 

Alright fellas. This weekend I took the truck to my buddies shop and got it up on the lift. I got the actuator off surprisingly easy. But when I took the cover off, to my surprise everything looked spotless in there. The contacts were clean as could be and making good contact with no arching marks. So I tested it with a 12v battery and the motor worked just fine. So I threw it all together and connected the electrical plug and tried to engage 4wd on the truck.... nothing. So my buddy puts it in what would be the 4-low position, and when I turn on the truck the motor sucks it back into 2wd. When I turn my 4wd knob my light flashes just like everyone else, and I can hear the relay click in the glove box. So now I'm stumped. Do you guys have any suggestions on what to look at now?

 

See if you're front driveshaft is spinning. If it's not the ADD it's likely the transfer case actuator of it jammed/bent shift rail in the tcase. The electronics first shift the tcase to 4wd then once it's in 4wd it sends a signal to shift the ADD collar over.

 

Got Lucky!!! Got all set to remove the ADD and decided to give test something. Got in the truck and turned the switch to 4WD and I could hear the motor working. Got under the and gave the ADD a wack with a 4lb sledge. Got back in and it worked. Tested, just like new, 4hi and 4 lo. Not sure how long before it does it again but happy to not spend the money now.

Thought would share to have others try prior to taking off.

2007 Tacoma

 

I guess I didn't realize that part of it. Thanks for the info, I'll give that a try next time I can get it jacked up.

 

Hey Guys new to TacomaWorld....figured id keep this thread going as ive got a quite confusing 4wd issue.

First off, truck is a 2009 Access Cab, 6 spd MT, Rear Locker, V6, TRD OR....i think thats it.

Problem:
Started off in 4wd hi (4x4 light solid), this last north east snow storm. Woke up, started truck, warmed it up, pulled out of drive way, turned switch to 2hi, heard the "thunk", 4x4 light stayed blinking. Shut truck off, turned back on, still in 2hi, light still blinking. Drove around for 2 days switching between 2hi and 4hi, light just blinked the whole time in either position....and it was always in 2wd regardless of switch position (almost got stuck multiple times). Day 3..in 2hi, light sill blinking, driving down road, switch to 4hi..."clunk"...4x4 light goes solid!!...Switch back to 2hi...light blinks forever...and pretty sure 4 was disengaged when i switched back to 2hi...do this all day with same results..light blinks in 2hi, but in 2wd, light solid in 4hi, and 4wd engaged.

End up reading all the Front Diff ADD posts...so tear that out...inside looks pretty flawless...solder them anyway, and the switch contacts too inside the case. Notice the small black gear inside the ADD has some teeth that look a little rolled over/worn down but not to the point they were no longer functional. Put it all back together.

Current symptomsAs have been stated by a couple of folks already)
Start truck in 2hi..hear relays (i think its relays...under the passenger dash) cycle...4x4 light blinks momentarily then goes out (normal i think)...front drive shaft not engaged, front diff not engaged. Switch to 4 hi after 30 seconds of truck start...light blinks.... ( but diff and shaft ARE NOT connected). Turn switch to 2hi, no relay click, everything stays connected, light still blinks. Turn off, switch still in 2hi, turn on light blinks then goes out, diff and shaft ARE NOT connected. Turn truck off, put switch in 4hi, turn on, light stays blinking but shaft and diff ARE connected.

So it seems like the truck / ECU goes through some master check during truck start, cycles the relays (2 clicks +1 if switch is in 4wd, only 2 clicks if started in 2hi....or vice versa) and performs the 4wd requested at startup.

Sorry for the dragged out post, just wanted to convey everything ive seen. Also took off TC actuator cover, the tracks look good, can see light witness marks but nothing that should be making a bad contact.

HELP!!!!! I cant give he dealer money after all of this!!!! Thanks for any info up front!!!!

 

I would put I up on jack stands and see what's spinning, your tcase actuator might be at fault

 

So I had all 4 wheels off the ground, which is how I was confirming what was engaged / disengaged...whenever I started the truck in 4 hi......manuall spinning the front drive shaft would turn the rear drive shaft (and I think both front tires if I remember correctly)...if I start truck in 2hi..manually rotating front shafts does nothing..no resistance...and front tires spin independently of one another...also when truck is started in 4hi..and I give it gas...everything spins..all 4 wheels off the ground

 

Mine had the same exact symptoms and it was the ADD actuator (front diff). It occasionally would switch to 4x4 hi with the light flashing. Had to switch to 2hi and turn off the truck to make it switch back. Couldnt ever get it into 4low with those symptoms.

Replaced the add (mine had water internally) and everything is working fine now.

 

Thanks for the quick replies guys! I opened my front actuator up...it looked incredibly clean (but like I said, the little black gear looked terrible). Idk...I hate to drop $300 on a new one just to have the same issue, but I guess i don't see any other option at this point...

 

Hello, I'm new here also, and I've also got this problem, I think. Anyway, I'm just curious as to what you gave the "wack" to, with that 4lb sledge hammer. Doesn't the actuator have a plastic cover. Wouldn't that break it. I read about people getting under there and tapping on the actuator with a small hammer, and I have done that, but no luck.

Also, I'm no mechanic, but have access to someone that can do the job. I've got a stupid question. Some people are referring to the "actuator" on the front differential, and some are referring to the ADD. I'm not sure what the ADD is ? Can someone help me?

Also, where can I get a new actuator. Is there a good place online to order one? My dealer wants around $400, plus labor, etc, etc.

I just want my 4x4 back..............thanks

(2007 Tacoma Access Cab with only 28K miles)

 

ADD is the automatic disconnect differential. I believe folks have been referring to the actuator in the thread when they use that term.

IMO the best way to find the best price on the web is to find the part number (I don't know it) and plug the part number into your favorite search engine. I found the part number for the transfer case actuator by searching that term the same way.

 

Thanks........I found the part number (41400-35033) from another forum member, plus I found the part (actuator) that I need, online. This forum is great......

 

x2 on what he said, so 41400-35033 is what you are looking for (the actual part is called the Differential Vacuum Actuator Assy...which is part of the ADD system, the part which apparently fails miserably).....just found one on ebay NIB $290 (out of PA)....theres a lot more out there for a little cheaper but they might be previous rev'd versions 41400-35032, 41400-35031 etc...

 

Thanks............yes I got the 41400-35033

 

Did the ADD last night and........we're back!!!!!!

You don't know how bad I wanted to rip open the new ADD pn 35033 to see what they changed/ why the part was rev'd at least 2x since the original!! But I decided against it ;-p .

Thanks for all the help TacomaWorld!!!!

 

Nothing changed, they are the exact same piece of shit stupid design.

 

Even inside the cover??? I would've thought at least they toughen up the black gear...and change that pos micro switch