Stuck In 4x4. Unsure If I Broke Something.

I apologize in advance if this has been addressed before, however I searched and did not find any posts specific to my issue, here goes:

Today I was backing up my 08 TRD Sport (Double Cab, Automatic, 4.0L) on a slushy/muddy dirt road. As my rear tires started to spin a little I decided to go from 2WD to 4X4 (High). I took my foot off the accelerator and waited for the engine RPMs to drop and listened for the wheels to stop spinning. After I heard what I thought was the back wheels stop, I switched over to 4x4. As I did, I heard aloud clunk in the drive line and a slight jerk backward of the truck. I continued backward about ten feet (front wheels were turned about 2/3s of the way towards the passenger side). I then stopped and put it in park to pick up the spent brass I had just shot .

Upon returning to the truck I put the trans in drive and switched the transfer case to 2WD. After about 1/4 of a mile on the dirt road, I noticed the 4X4 light on the dash was still flashing (I am used to it taking a second to engage/disengage).

I continued to drive another 1/4 of a mile before I put the trans in neutral and let the truck roll backwards for 20 feet. Still the 4x4 did not disengage.

At this point I drove home (approximately 10 miles of paved roads) with the 4x4 engaged and the switch on 2WD (dash light flashing).

Upon pulling into my driveway I went from reverse to drive a few times with no change in the 4x4 (light on dash still flashing and 4x4 still engaged).

As a last resort and due to a few post reads, I let the truck run for 30mins in park to heat things up (outside temp was about 40F) and then returned and attempted to switch from 2WD to 4x4 and back a few times. Still nothing. I even went between drive/neutral/reverse several times moving a few feet in each selection.

Now my truck sits in my driveway stuck in 4x4. Id really prefer not to take it to the dealership if possible because I know its going to cost me a grand or more (vehicle is out of warrantee). Any input would be much appreciated here. Thank you in advance.


Note: 70k Service was done (by me) with Mobil 1. The transfer case and diffs have fresh oil in them as of 9k miles ago, and all chassis points have been lubed.

Also, I Iifted the truck apox 3”s and put 31”s under it (several months ago, Ive used the 4x4 since with no issues). This was done via a Readylift SST kit (I know I know, I was on a budget), and I also did the front diff drop to go along with the lift. Lastly, I have 1.5" hub centric wheel spacers if that makes a difference.

 

try switching back into 4hi/4lo then going back to 2wd.

 

No dice.

 

Well just for future uses I personally wouldn't ever engage 4x4 while in reverse. My truck has the same clunking noise and it doesn't sound good so whenever I engage or disengage I go from neutral to drive just to be sure nothing's engage or grinding. As far as fixing the problem when I did this the first time the same thing happened and the way I went about fixing it was simple. Back out of your driveway put it in park or neutral and flip the switch back to 4x4. It should stop flashing after a few seconds. If it doesn't drive forward a few feet till it does. Once it does then put it back in neutral or park and disengage. When disengaging 4WD you can be driving forward or at least rolling. I just let off the gas and flip the switch and stay off the gas till the light stops flashing which while your driving happens almost immediately most of the time. My buddy just took apart his actuator in his rear diff. He has a OR so he has the e locker but the same thing was hopping to him as well and also his locker would randomly engage and stay engaged even though he wasn't in 4L. He found that when he took it all apart it was full of water and dirty and rust and who knows what else lol. I don't think yours has this issue since its so new and hes is going on 160k with the original actuator haha but that's the next thought that comes to mind if none of this works. You could've also misaligned the actuator, if so you'd have to pull it and realign. Try my first solution and see what happens. Just remember don't switch to or out of 4WD in reverse without letting the truck roll forward and disengage itself. Hope this helps.

 

Disconnect the battery for a bit and reconnect.

 

^^Try this

Are you sure 4wd is still engaged (are you sure it ever engaged to begin with)? I've gotten the flashing light going from 2wd to 4wd if it doesn't engage at all. Do you feel the drivline binding when turning?

 

Im sure 4x4 is engaged. It pulls like it is and shimmys a little when I turn on black top.

 

Likely the contacts inside your actuator are corroded or dirty/condensation....you will either have to replace the actuator or take it off and clean all the contacts.....just have to diagnose which of the two actuators...Good luck but a fairly common issue

 

Is there a write-up on this?

 

There was one on the FJ Forum some time back but it cant find the one for the transfer case actuator. Let us know how you make out. Good Luck

 

Update- Roughly 48hrs later and after tying the following:
*letting it run for 30mins to warm everything up and moving the switch
*disconnecting the battery for 30mins
*checking the fuse
*going between Neutral,Reverse, and Drive mutiple times
*looking at the accuators to see if there were any wires disconnected
*and so on....

I decided to drive to the dealer to have it looked it. While enroute, the 4x4 went out and the light stopped flashing. I then attempted to put it back in to 4x4 and back to 2WD, all worked as its designed. However, later that day, I needed to use 4x4 in the snow and low and behold it wouldnt go in. So I suppose it time to make an other appointment with the dealer and have this professionally looked at. I was just hoping to fix this my self. Ill keep you guys updated. Thanks for the input again.

 

I can get with my buddy whose pulled his actuator and see what info I can get as far as how to do it if you want. It's not complicated. He had it out,completely taken apart cleaned and put back together in just a few hours. No special tools needed just basic tool set. Let me know and I can get it for u before you go and pay a dealer. I know he took pics of the actuator after it was out that I can get as we'll I'm not sure about pics taken during the whole disassembly process.

 

That would be awesome. Im sure it would help other TacomaWorld users as well. I appreciate it.

 

No problem.

 

Update 02/03/13: I took the truck to the dealership and the problem ended up being the front differential actuator. One of the solder connections was broken. The dealer replaced it and also highly recommended that I engage/disengage the 4x4 monthly to keep everything moving and freed up. I had the truck out in this blizzard last night helping a buddy snow blow and she ran like a raped ape. Got through 2+ feet of snow with 31"s and 3”s of lift. I was impressed how well it did. Thank you all for the input.