Toyota transfer case ?

I have a 1996 Toyota Tocoma ,4x4 3.4 engine with a manual five speed transmission , my question is how can I tell witch transfer case I have? The one I have has an actuator on the back end near the rear drive shaft! The front axle has what looks like another vaccumn actuator on it as well,i do not have manual locking hubs if this helps any, the computer ask if I have---

6 cyl, differential lock (with automatic disconnecting differential)
6 cyl, w/o differential lock; MT, automatic disconnecting differential
6 cyl, w/o differential lock; MT, w/o automatic disconnecting differential; shift on fly
6 cyl, w/o differential lock; MT, w/o automatic disconnecting differential; w/o shift on fly

thanks for any help as this is my first Toyota and really like it other than transfer case problems, and any suggestions where I could get one ? I called the dealer and all they could give me is a part number

 

First, what is wrong with your current diff?


Second your truck would be the second one.

 

The dealer said the actuator went out? I just bought this truck and the four wheel drive was working , I took it out of four wheel drive the next time I went to use it and the transfer case wouldn't engauge the front drive shaft so I tapped on the transfer case actuator and it worked I took it back out of four wheel drive then put it back in and nothing again so I tapped on it again and nothing no matter what I did so, I took it to the dealer and they said the tranfercase actuator is no good ,and gave me quote of 2400 dollars so I was looking for another transfer case hopeing to find a used one cheaper then what the dealer wants to fix this one!

thank you for your time and responding , as I am totally lost on this

 

Is changing the transfer case my best option ? Any ideas really don't want to spend 2400 dollars at the dealer,they seem kind a high to me!

 

http://www.tacomaworld.com/forum/2nd-gen-tacomas/263525-how-trouble-shoot-4x4-actuator.html

 

here is a pic of my transfer case actuator




here is a pic of front axle actuator

 

. From the pics you took , the link I posted should give you all the information you need to properly diagnose the problem but it sure sounds like the actuator on the front differential to me . Do you get a light popping up on the dash to show you when it goes into 4X4 ?

Edit " the pic shows a vaccum controlled actuator on the front diff so you when you select 4x4 , vacuum pulls the shift fork into 4x4 . You wanna make sure you have vacuum at the front actuator when you select 4x4 and the truck has to be running to check . I highly doubt you need a new transfer case ...just a little tlc

If you have an actuator on the rear of the truck ( rear differential ), I beleive it should be this choice

6 cyl, differential lock (with automatic disconnecting differential)

 

I would make sure your vacuum lines are in good shape.

 

here's a pic of the truck ,if you push the button in for the 4x4 before you start the truck, then start it with the button in the light will come on and flash and a loud beeping noise sounds, if trucks running and you push 4x4 button in nothing happens no light or any thing, and front drive shaft never spins no matter what I do!

 

ok I checked the front actuator with a vacuum gauge I had good vacuum with the truck running , I used a test light to the front actuator switch and heard some clicking or switching up on drivers fender well , I looked and do not have an actuator on the rear diff...just abs wires, emergency break cables and break lines is all

thanks for your guys time ,I do appricate it, I feel kind a dumb as I am usually fairly good mechanic, but this is totally new to me!

thanks gearcruncher I am going to read on the link you posted and see what I can figure out!!

I put vacuum lines back on front actuator did not hear it in guage or making anything move or no noise tho

 

So did you check vacuum at the actuator on the back of the transfer case? I would have to guess either a control valve is no longer working or your vacuum lines are leaking. Seems odd it was working but now its not.

 

Check your pm

 

No I didn't check for vacuum on the transfer case actuator as I believed those are just vent lines and theirs no where for vacuum to be pulled from, getting late now but I certainly check them tomorrow! the thing I'm puzzled with the most is I tapped on the transfer case actuator the first time it quit and it worked the one time, and now no matter what I do it doesn't work , Comatized;8554655 do u happen to know where the control valve is on my Tocoma by chance?

 

The small switch on top of the transfer case with the two wires ....think you need a 1 inch wrench to get it off is famous for sticking . Take the switch off and make sure its moving nice and free . I am willing to bet its stuck . Its just a ball and spring type switch that seizes up without constant use .Once removed , Spray some lube at the ball until it begins to move. That switch tells the vaccum pod on the fender well to send vaccum down to the front differential actuator .


The switch on the front diff also gets stuck . That one tells the light on the dash to illuminate . If it gets stuck , your 4x4 light will stay on all the time even when you take it out of 4x4 . Might as well take that one off and lube it up too

 

Thanks gearcruncher I will do these things as soon as I get home today from work, again I thank you guys for your time !

Can you guys tell me about the shift on the fly is there a chance I have it on this transfer case?

 

Nice truck I hope you figure out your transfer case issue

 

Shift on the fly is being able to shift in and out of 4wd while in motion which I can't remember if our trucks are capable I prefer to be in N... And not moving sometimes it makes a little noise shifting in and out but I'm sure that's common on the 96's

 

I did figure it out.Nice truck to you too! I did have a bad transfer case actuator ,they are very expensive . Dealer est. was $2400 for parts and laborer, parts was $1350,and $872 dollars for laborer and $95.00 tax,saying they had to take out the transfer case and open it up to change the actuator, I wouldn't pay that so I ordered the part witch was $1200 and something , and I put it in myself with out removing or splitting the transfer case, dealers are a rip off...
Thanks again to all the guys that gave me ideas and help , this is a good forum and good people!!!

 

I know this is very old but I'm having this problem now and I have a feeling my front diff actuator is done, I would rather try to check the switch, do you by chance have any pictures of where I'm looking for a switch, also have you ever heard of anyone taking the actuator apart and cleaning it to make it function properly? Or is that just not what you do

 

Hey,
Trying to follow this thread as I think it pertains to my issue, but none of the pictures are working anymore. Anyway you could post up a pic of which switch on top the the transfer case? I pulled off one that was near the actuator, but it wasn't stuck, and cleaning it made no difference. I do see several other connections to the transmission and transfer case, but not sure what is what.

My issue is similar I think. I have 5 speed mt with a manual 4wd shift lever, no push button. Vacuum actuated ADD. I can shift out of 2h, but I cannot get into 4h, I can get into 4L, but front wheels do not engage. 4wd light never lights up or flashes. No matter how hard I pull back on the lever or how much I go forward and back the shift lever will not actually pop into 4h. The front drive shaft is engaged with the lever pulled out of 2h as I can't turn it freely with wheels on the ground, but no 4wd and it wont pull all the way back into "gear". The lever appears to be in N position.

I pulled the vacuum tubes off of what I believe to be the 4wd vsv's and there is suction coming to both the brown and the blue valves, one of them has suction going out, and one does not, I don't remember which was which right this second. I assume this is likely the normal 2wd state of affairs.

What I don't understand is (well a lot).... what action makes the vsv's switch? As in should moving the 4wd lever initiate a switch, and is this the switch that is stuck? Would that switch not moving the actuator prevent me from getting the lever into 4H?
I have not tested the vacuum on the hoses going to the actuator as I don't have a tester, nor have I tested the vsv's cause I don't really know how.
If the actuator is not switching is that reason enough to prevent the lever from actually going into 4H gear? Or is the lever being blocked some how ?

Thanks for your help, Its a 2000 tacoma trd with locking rear diff, 6 cylinder. MT, 215,000. And full disclosure it was just towed to the shop after the radiator cracked, radiator was replaced and system purged by professional mechanic shop. No engine damage, didn't over heat. I watched the guy who towed it, just winched it up onto flatbed connected to the frame and in neutral. 4wd used once since I had it back from the shop.