Cracked Transfer Case Actuator

Here is the entire story if you want to read more: Driveshaft failed...Please Help!

So I was a ding dong and didn't grease the joints on my driveshaft. They rusted, cracked, and the front joint on the rear driveshaft spun apart yesterday. Since it was still spinning when it broke apart, it carved a nice arc in my undercarriage. It ended up cracking the connector and transfer case actuator as seen in the picture below.

Any help on how to fix/mend this transfer case actuator is greatly appreciated. Links, DIY tutorials, part numbers, suggestions, anything would help. Thank you.

 

Lesson learned?

 

OH my god, yes. Totally. Feel like a total loser today.

 

Shit happens, just fix it and move on.
Have your drive shaft checked for true and balance before adding new U joints

 

Thanks, I'm trying that. Just gotta scrape together the money for everything. But yeah should be ok.

Good advice, I'll make sure that happens, thanks.

 

I didn't zoom in enough when replying about the cracked connector in the other post. Yeah, that actuator needs to be replaced. There's a trick you can use to remove it leaving the shift fork in there, search for posts about the actuator to get more info about it. This video describes timing the actuator so you avoid confusing the computer and being unable to switch drive modes.

 

Ahhh haha ok sure, I will replace it then! Makes sense.
Thank you so much for that video and the information.

 

You could just get a cap. Could try and used junkyard or you could buy a new one and just install the cap. I would explain how to do it but better if you do your own research and see if you feel confident with the process. It’s very easy to do but you can mess it up and it can be time consuming getting the timing correct if the inner gear comes out

 

Hmm, yeah for sure I will totally look into that and do my own reading. I really appreciate it. Yeah I will not attempt if I do not feel confident about it, for sure.

 

I'm sorry for being so uneducated about this, but I'm trying do as much research as I can to just replace the actuator, but I'm having a little bit of a difficult time.

I found this video that makes it sounds super simple: https://youtu.be/kdh8tlxfgnU
@Leomania is this the trick you were describing to leave the shift fork in there? In this guy's youtube video he just says to put it back together you just reverse the order. But he removes this gear at the very beginning and I'm wondering how easy that is to get back in there the correct way?

Anyways, I'm obviously doing as much reading as I can, but any more links/videos/suggestions would be helpful. Thank you.

 

The main thing is you want the contacts on the actuator gear to be in the same position as the transfer case rack when you put the gear back in.

https://www.tacomaworld.com/threads/4wd-system-operation-help-thread.742420/

 

A new connector and replacement is in order. Make sure to set the limit switch timing properly during reassembly.

 

My post has a link to this video, he shows it pretty well I think:

https://www.youtube.com/watch?v=GCY2BCdlU4I

 

I didn't read the entire thread on the failed u-joint but just so you're aware, if you ever have a rear drive shaft failure like that again you can remove the rear drive shaft, put the truck in 4-hi and drive it home. Because there is no rear driveshaft you'll only have front wheel drive and there won't be any issues with binding.

If the actuator doesn't work 4-hi is going to be one "click" on the shift rod if you had to do it manually, 2 clicks is 4-lo.

 

Those are a different style actuator at least the second video is. Remove the cap 3 10mm bolts usually the gear stays in place. You can mark the gear if you like. But it should stay inside. Since you have a big hole in the side u could use a screw driver to hold it to make sure. If you remove the cap and see that the gear is damaged you will need to mark it and install the new one. Unless the gear comes out or it’s damaged out u just put the new cap on very simple.
At this point I don’t think you have much to lose so send it

 

Right you are. Apologies @greatsaints for botching that.