transfer case problem

I have 2004 Tacoma 210,000 mi. the transfer is starting to not want to come out of 4hi to easy. it acts like it sticking in 4hi and when it comes out I can hear a small clunk it does not do it all the time but seems to be getting worse. I am doing this on slippery roads

 

Hows the fluid level and when was the last time it was changed?

 

If you're trying to shift in/out of 4hi while under power (foot on gas), there will be some slight binding as the ADD shifts, especially if the wheels are slipping. When you shift the transfer case, take your foot off the gas, shift it, and then reapply power when you feel it shift or the light comes on. The "clunk" you're feeling is probably the gears meshing in the differential, which is normal.

Also, when was the last time you changed diff and transfer case fluids?

 

I just reread your post, is the clunk coming out from the front of the truck, or from the transfer case? If the light stays on for a second after you shift out of 4wd and you hear a clunk out of the front end and the light goes off, that's normal as that's the ADD shift collar disengaging the front axle. It will do the same thing shifting into 4wd, it may take a second and you will hear a clunk from the front and the light will come on.

 

i have not changed fluid in 120,000 mi.. i always take foot off gas when shifting out of 4whd. the clunk sounds like it is coming from transfer case but is hard to tell. the lite goes out when you hear clunk or it disengages 4hd. the diff. fluid was changed at same time.

 

Uh, go change the fluid in your transfer case and diffs. Regular maintenance interval for those is every 30k miles.

 

one other question does any one think there is a additive I could put in when I change the fluids that could help it disengage smother

 

I changed all the fluids in both diff. and transfer case. went with 75-90 full synthetic. made no difference. like I said it does go in easy at all speeds but does not disengage easy until you are stopped or slow down to about 5 to10 mph. any ideas about what parts could be getting worn out.
thanks again hunterjo

 

Put the transmission in Neutral then try.

 

I will try that later today when I go out in the snow storm we are having now. I live in mi. close to lake mi.

 

I tried what you said and seemed to help. I also tried letting it coast down a little still in gear and that seemed to help. so my thought is I have some worn parts in my front diff. any ideas?

 

Honestly it's probably just because there's still a load on the drivetrain from where you came to a stop or are holding the brakes. I have to fiddle with mine every now and then. I wouldn't worry about it but mine's a wheeler not a dd so it doesn't matter to me if I have issues.

 

I have update on my test drives. it seems that the dryer the roads are the harder it comes out of 4wd. on icy roads it disengages real easy and on partly wet to slippery roads it becomes harder to disengage and dry roads you have to almost come to a stop before it will disengage. does anyone have idea on what is wearing out.
thanks again hunterjo

 

120,000 miles without changing the fluid? Wow...

Might be time for a rebuild man.

 

Why are you changing it while rolling?? I always am stopped when shifting the t case

 

the Tacoma transfer case is shift on the fly. It is designed to be shifted in and out while on the move or stopped.

To the OP, it is harder to come out of 4WD due to the binding on the drivetrain. Follow the shifting instructions in the owner's manual.

 

Hm, I just always stop out of habit and precaution in anything I'm driving. I'm also not running tacoma tcases in my tacoma sooo yeah..