How To Trouble Shoot 4x4 Actuator

I have seen a lot of people replacing actuators, which are very expensive. My 4x4 went out a few months ago and I went through the attached factory trouble shoot guide, and found out the two tiny prongs on either side of the actuator motor were barely bent so they couldnt make contact. I soldered the prongs to the motor and everything worked fine:

 

thank you, i was kindof lurking in that thread and am sure this will benefit many of us a few miles down the road

 

That is some good info.

 

Is this what your t case looks like?


Photo from DCtacoboy4x4

Do not touch transfer case.
GO to front diff.

 

The 4x4 actuator is at the front diff

 

DO this!!! It worked!!!
I will post up more pictures to help out future people
THANKS again MAN!!!!

 

I had to drop the two front diff brackets to get to the top 2 bolts.



I ended up replacing the vacuum hose because i cut it a little while replacing it.



This is what it looks like out of the diff. Make sure you clean the old silcone gasket off before installing.



Top side with the 5 screws you have to remove.



Here are how my terminals looked. They looked pretty close but i could see ark marks on one side.



My soldering looks poor here but i touched it up before installing.
I soldered both terminals on the motor and both on the switch as well just for insurance.

And then reverse order to assemble.
Thanks again blackhawke88 +1

 

glad i could help!

 

Good work to the both of you!!!!!

Send blackhake88 some beer.


Mods, make a sticky out of this.


As for the dealers, shame on you for trying to rip off the owners.

 

Mine was the T-case actuator. It has three slide contacts that corroded. I tried to fill the pitting with solder and sanding it flat, which worked for about a year, then I converted my T-case to manual shift and just locked the front diff actuator then unplugged it. Works every time now. Both actuators are a really bad design and the weakest link in the factory 4wd system.

 

Agree with you.

 

I concur

 

Def gana have to try this when I get home from deployment in st paul island.
cause this is my problem

I can shift into 4wd hi and I hear it click in but the light just keeps blinking. Then when I got to switch in into 4lo while I'm in neutral it doesn't shift and just keeps beeping. Then the only way I can get out of 4hi is to shut the truck off, then switch to 2wd then turn the truck back on and it will then click out.

Any ideas?

 

Did the trick for the time being! I also had some faint arcing marks on one of the prongs, soldered it and works perfect. Beats paying $650 for a new actuator! Thanks!!

 

Marking this one in my browsers fave list for later.

I wonder thought, is this a FIX? or is this more like a temp fix like a band aid on a broken leg? Whats the real cause of the actuator failing just those prongs losing connection?

 

Somewhat. There actually is NO solder at all on those contact points. The are only making contact by simply touching. That is why this fix works by adding solder. It makes a permanent connection that does not allow vibrations to effect the contact points.

 

Unfortunately no. That is why several people have claimed that they could see tiny arc marks (myself included) where the pins were trying to make contact but did not have a good enough connection.

 

Almost makes you wonder why manufacturers are placing electrical components in such a harsh environment under the vehicle doesnt it ?
General motors is by far the most guilty of this placing computer boards on the transfer case , abs controllers on the frame rail etc etc .
All it takes a quick trip through a shallow pond to find out how well these components are actually sealed .
I am not saying water impregnation is the cause but I sure miss the days of a manual 4x4 transfer case shifter in a Toyota .

 

Subbed for future use. Thanks! :thumbs up:

 

How much gear oil do you loose when pulling the actuator? Can I use regular gasket sealer when I hook it back up? Can I use hand tools only or will I need access to an impact wrench?

Thanks!