No 4WD--at a loss

Hello,

My son was driving his 2009 Tacoma when the pinion sheared from the drive shaft flange causing the drive shaft to flail around the underside of the truck until he got it stopped. In the process of flailing around, it took out the actuator on the transfer case and bent the actuator arm. Decided to replace actuator AND transfer case (instead of cracking it open to remove bent arm), and after reassembling everything, the truck will not enter 4 H or L (get a green flashing 4WD light in 4H AND an amber light and beeping when in 4L). Rechecked ALL electric connectors on actuator and vacuum lines, but can't find where the vacuum lines go into the engine (they join a T connector just downline from where they attach to the transfer case, but I can't trace them into the engine).

Went through the troubleshooting procedures in the manual and nothing--any suggestions? Just spent $700 on parts and a full weekend of labor...very frustrating.

Thanks.

 

Welcome !!

What caused the flange to shear off or did the nut come loose??

Just a guess but you went with a used case ??

Did you check things moved before installing ??

The case works like it should in 2wd??

 

Hello,

Metal fatigue although my mechanic says that by lifting the truck, it put undo stress on the shaft.

Yes on the used case (everything turned and put new fluid in it).

Didn't know how to check for any movement without vehicle running. Should I have heard the arm moving when selecting between 4H and 4L if not running?

Yes.

Thanks!

 

double check the connector onto the t-case actuator. The vent should have nothing to do with it not shifting, but the actuator vent and top plate (where a normal manual shift lever would go) Tee into each other then head up to the top of the transmission bell housing for a vent. Hopefully the transfer case you bought was in good working condition, perhaps the actuator on the "new to you" one has shit the bed?

 

Thanks for the reply and I'm not sure I understand the reference to the actuator "vent", or the top of the bell housing for a vent (are your referring to the two vacuum ports on top of the transfer case?). I rechecked all electrical connectors (one black and two grey) and they're all fastened securely.

No, the actuator is new.

 

by vent I meant vacuum line. They are not a vacuum line, so like I say before they would have no affect on the transfer case shifting in and out of 4wd. The position sensors (2 gray connectors) could also be bad. You can remove them with a deep well socket and check them with an ohmmeter. Push the detent in and should be closed switch, and with the ball retracted it will be open.

 

Hello again. Rechecked all connectors and when the truck is not running and I activate the selector on the dash, I DO hear the actuator moving when selecting either 4H or 4L. However, it still doesn't engage when driving.

Going to take it to a shop on Monday. Just out of curiosity, what ARE the two nipples (with the black hoses attached to) on top of the transfer case for? Venting?

Thanks.

 

They are vents for when the case heats up and cools down so that it vents to atmosphere to keep the pressure or vacuum off the seals.

 

Same thing happened to my 2013 but all the metal looks good just cracked plastic, can pieces of actuator be replaced or do I need a whole new unit?

 

Instead of the word "Vent" we usually say "Breather"
Gearboxes and differentials have breathers, either on them or more often at the top of a tube going up high from them.

 

Hello everyone. Was going to create a post but, this post is a similar issue.
My 4wd and 4lo light started flashing while driving home in heavy rain, never tried to engage the system. Surfed the forum and did everything suggested, with no avail. It turned out to be a corroded connector going to the ADD. A new pig tail cost $24, the pig tail goes from the actuator motor and connects to the wiring harness. The connector going from the wiring harness was corroded to.
I cleaned up terminals and used some dielectric grease and it seemed to fix the issue.