4WD doesn’t engage

I’ve got a 2003 V6 Auto with a push button (not the J shifter) 4WD lever. When pushing the button it no longer goes into 4WD, nor does the indicator light go on. Local mechanic diagnosed and said the button is fine, appears to be the actuator inside the transfer case. He can’t split the case and repair it, so looking for options. Thinking it may be quicker to just get a remanufactured xfer case and have the local guy swap it out (he quoted $700 labor) than bring it to a Toyota dealer and have them service it at their ridiculous rates.

Truck only has 87k miles on it. Any recommendations are appreciated!

 

Be a little careful with the actuator- if you take it apart it's really hard to get back together and positioned correctly.

It's not unheard of for these actuators to fail. But I'd start simple and use an electronic contact cleaner to clean the harness connectors. On both the xfer case and ADD fork. Pull them apart (it might be a PITA) and hose them down, get a q-tip in there, get all the road grim out, and let them dry, and connect everything back up.

 

put in drive and reverse, just put manual

 

Thanks Andy. Great suggestion.

 

If that doesn't work. I would look up how to remove the actuator (again, taking the actuator apart is no-going-back $1k mistake according to a thread on here Actuator Transfer Case Timing. I haven't personally tried) and see if you can manually engage the 4wd, with the thinking that maybe the internal bits are just a little sticky. Put the truck up on jack stands etc...

I'd repeat the same for the front ADD actuator. Rule that out as a cause as well... Then reassess, and see what xfer cases are floating around out there.

 

You can try to apply 12v to the correct pins and see if the actuator moves or not. When I did my 4wd conversion I activated it and left it

 

Start with the basics... check the fuse. see INS2-4 pdf.



I don't know why he says he can't open it up and repair it. To give you an overview of getting to (if replacing) the actuator and tearing down the case, see this video. While the tcase in the video is from a newer tacoma, it is actually very, very similar. Also below, you'll find teardown instructions for your case.

BTW, if you were local, I'd help you swap it out (the tcase). $700 bones? Do it yourself brother.

https://youtu.be/DlOm8_Tt81c

 

This is what the local mechanic did, determined that the switch itself was good, but that it wasn’t getting a response from the actuator within the xfer case.

 

thanks Mike, I really appreciate both the docs and the offer. I haven’t been doing too much wrenching lately. This is my only ride and work is making it a challenge. Going to see if this is something I can handle though.

 

Not trying to influence one way or the other, just passing on as much info as possible. Taking the case apart, you absolutely have to follow the steps laid out. No shortcuts.

If you run into any issues, shoot me a pm and I'll try to help.

GL.