2001 TRD double cab Transfer case swap options?

I can't get 4x4 to work in my recently purchased truck with 117,000 miles. It was stuck in 4x4 with no 4x4 light on , no movement to either TC selector or ADD unit. Figured it could not be too hard to get working again- LOL! Been working on this for 6 days with factory wiring schematic checking connections and voltage with interior pretty much in pieces and I'm just about done messing with this "funked up" system.

Can anyone please tell me which year/ model manual shift transfer cases will fit on my automatic transmission? I know I would also need transfer case linkage to make it happen. I'd be ok just locking the front diff collar together to get out of this mess.

I'd rather swap T case do than spend big $ on more plastic crap that from what I've read will only be problematic down the road and may not solve problem.

Thanks

 

Are you just not getting voltage to the actuators? What about the actuators themselves? Do they work?

You're pretty much talking about a manual hub swap, plus T-case swap, just because you (likely) have a wiring issue. Seems like a lot of work.

 

If you ever looked at the 4x4 schematic and then looked under the dash Maybe you would understand why I'm looking for a way out. If you've been there I apologize LOL. Im good at inserting foot in mouth sometimes. lock out hubs and a transfercase shifter have been replaced with around 50 connectors and relays connections, about $1300 worth of actuators, a $500 4WD ECU, wire looms that Houdini would have trouble getting at. It also has a connection into engine control module. Not just toyota to be fair. Price of both actuator units and ECU would exceed a used manual transfer case if I knew which one would work and I'd be done with it! Sorry for the rant!

Voltage is getting thru to actuator connectors as it should based on button pressed. Since 4x4 light is on separate fuse, would think that in the event it is burned out, that the actuators would still function. I guess it could be one or both actuators but they look clean inside and leads test out good. Motors operate off of the gear assembly. Service manual says to test actuator(s) motor assembled fork / gear units movement using a relay but does not show how to hook it up? It says don't apply battery voltage to motor leads with gears intact or actuator will be damaged. I have an idea but don't want to take a chance. Any suggestions on how to bench test actuator as a unit would be helpful.
No corrosion or cobbled up old wiring of any kind. I'm running out of leads without just throwing $ at it but that might not solve this issue?
This Truck did not see a lot of 4x4 use with only 117,000 miles.