How To Trouble Shoot 4x4 Actuator

Went to do this today, and cant get the dreaded 4th bolt out, the lower one on the side of the vacuum line. Did most of you guys pull the front diff bracket like this? https://www.tacomaworld.com/threads/how-to-trouble-shoot-4x4-actuator.263525/#post-6450282

Or were you able to do it with a wrench? I cant seem to get enough clearance to get it.

Also if I pull the diff bracket, do I need to support it somewhere?

 

theres a mount on the back of the diff you can remove the front mounts

 

Is it as simple as it looks? Just 3 bolts to remove the pass side mount?, maybe 18mm?

 

I just kept fighting it and was able to get the bolt out. I bought a 6 sided socket that was just a tad bit longer than your standing homeowner set and it did the trick

 

it’s just a couple. Not hard to do. I would just use the e14 with an extension and a swivel socket

 

So I was able to finally get the actuator off after getting a longer socket. awesome suggestion. @JDL1 Unfortunately now all the screws are heavily corroded. Tried wire brushing them and picking them out but no dice. Has anyone tried to dremel off the heads then pull out the screws?

Or should I just get another actuator?

 

try spraying with a penetrant. Use an impact screwdriver to loosen.

 

Yeah, Im soaking them overnight. I cant a good grip on them. Tried about a dozen philips heads. Keep slipping. Vice grips also slipping.

Update: ordered a new one. Ground the heads off with dremel and everything corroded inside. Also appeared what looked like white battery dust.

 

Question for the new part install. Using this site as a reference. http://www.4x4wire.com/toyota/tech/add/

When I took off my 4WD actuator, I was in 2wd and the fork was to the left in this picture. Is that correct, or did it slip past where it is supposed to be?

 

I had to slide mine all the way to the drivers side to get the new one on. I gently pushed/pried with a flathead.

 

@JDL1 did you push with a flathead on the actuator fork or on the pulley inside the front diff? Is the fork supposed to be between the pulley lines? Mine was to the left of both of them

 

I didn’t/couldn’t move the fork on the actuator. I pushed the “collar” inside the diff over toward the drivers side since the fork was moved over to the drivers side when I unboxed it. The fork sits right in that groove

 

Sorry if this has been asked, but I didn't see this particular question answered:

Will the front actuator engage/disengage if the TC actuator is not working?
My 06 Tacoma starting the dreaded blinking 4 lo light. I switched back and forth from 2hi to 4hi and it engaged in 4hi (now stuck in 4 hi).
I took the front actuator out and soldered the connections just in case.
With power applied to the motor contacts, the fork would move back and forth freely.
I tested it with actuator plugged in (but not bolted up) and the switch does not have any effect on it.
Thanks

 

no

 

Simple enough then.
Time to work on the TC actuator.
I'm hoping I can just take the cover off and clean the corrosion.

 

Got it fixed. I removed the TC actuator cover and found the outer ring was corroded. A little emery cloth and dielectric grease later, everything works as it should. I also replaced the vent hose to make sure water doesn't enter again. This really is a poor design for a critical component..

 

Which screws bolts did you take off to get the cover off?

 

I got a question guys. There may be an answer already in here but that's hundreds of posts to look through, at least.
I have a 2nd gen & had the whole front diff replaced cause 4 wheel drive wouldn't engage (more to it but that's the short story). At a dealership.
I used to be able to engage 4x4 while driving at a lower rate of speed, say 35-40, if I was coming up on some snow blown road. Or engage it on a dry road before getting into mud...now I can't.
Took it back, we drove around the dealership a few times and got it to work and they say it's fine but I know my truck & I should be able to put it in 4x4 anytime I want, wherever.
It has a Magnuson SC so even when it rains I need that help to get going in the rain from a stop light up to 25mph.
Can anyone give me an idea what the prob might be so I'm better prepared when I go to the dealer, so they'll listen.
Charlie

 

The 3 10 mm bolts on the black cover.

PS, I found this video to be helpful: https://youtu.be/n3NN5wYbDqA

 

Browsed most of this thread and have not seen a problem quite like mine

I had problems with both the front ADD (motor rusted solid) and also the transfer case actuator (contacts corroded).

I've purchased a replacement ADD (Cheap ebay), and repaired the TC actuator. TC actuator motor moves freely in both directions. I get good continuity between pins 3+4 (4LO), Pins 4+5 (2HI) and pins 4+6 as needed in each position. Never more than one pair at a time (which would be bad). Resistance less than 1ohm.

Limit switches tested OK, but I replaced 4Hi anyways.

If I take the ADD and manually apply voltage to the motor pins to 2WD position (collar closer to 'box'), place actuator in 2HI position and verify by testing continuity at pins, push the shift lever in to 2HI, attach actuator to shaft and install gear, and do not connect limit switch connectors, there is NO blinking light. If I plug in the limit switches, all is still good (therefore eliminating a sticky switch issue - I believe if ADD is in 2WD, actuator is in 2WD position, but a limit switch is triggered, the 4x4 light will flash, correct?)

When I move the switch to 4HI position, there is a successful shift to 4HI. The ADD moves AWAY from the "box", and the actuator moves to 4HI position, verified by removing connector on the actuator and checking the continuity on the pins (4+6). The 4HI limit switch also now has continuity.

Problem is, the 4x4 light will not stop flashing. If I attempt to switch to 4LO, I hear clicking from the 4x4 computer and beeping (if in Park) or no beeping (if in Neutral). 4LO light flashes, no shift occurs. If I shift back to 4HI position with knob, 4LO light stops flashing, but 4x4 still blinks.

If I shift back to 2HI, the 4x4 light continues to flash. There is NO shift of the TC actuator. I don't remember this second (not home) but I believe the ADD also does not move.

I haven't started taking readings at the 4x4 computer for continuity yet.

My *guess* is that maybe the limit switch in the ADD (new) is not working? Because if the 2HI -> 4Hi shift starts with the TC actuator, that shifts successfully, then the ADD moves to 4x4 position (away from box), but somehow the computer is not receiving the signal that the ADD has moved, causing the blinking 4x4?

I haven't checked any continuity on the ADD yet. It's "new" but also cheap one from eBay, could be defective?

When going from 4HI to 2HI, what operation needs to occur first? ADD movement or TC actuator shift?

Any other thoughts / anyone seen this scenario?