09' 4WD TACO ISSUE WITH TRANSFER CASE (STRIPPED GEAR SOUND)

FRONT WHEELS RECEIVE NO POWER IN 4H.

Hello,

I have a Tacoma 2009 Double Cab 4wd 5AT with ~155,000 miles.

I have attached video links so you guys can hear what it sounds like and where specifically the noise is coming from:

https://drive.google.com/file/d/1frritGxqDi92J9egGn7P9N_LAneBT7Ai/view?usp=sharing

https://drive.google.com/file/d/1fvGr1u0uVLvDC1w8pDpDdcXWlQcWe8LC/view?usp=sharing


I wanted to hop on here and see if anyone has advice on fixing an issue I've been having with a noise that's coming from my transfer case. When the truck is in 4H, low speed (<5mph), the front driveshaft is not being driven so the front tires receive no torque at all. I confirmed this because I lifted the front wheels while the truck was in 4H and was able to spin the front driveshaft by hand. Also, the mud at KOH confirmed that my front wheels were getting no power. At the same time a loud sound of a stripped gear comes from the TCase.

In the past when I was having the shifting into 4H and 4L issue, the sound started and it only comes at very low speed, when sending low end torque.

I've already replaced my front diff ADD with an OEM Toyota actuator and the TCase actuator with a non-OEM one because I was having issue with my 4wd not working. My original actuator was very corroded inside so replaced it with no luck. Finally took it to a mechanic and they diagnosed the issue as the ADD, so I replaced it with an OEM one. I was able to get rid of the 4LO flashing light by hitting the TCase shifting rod all the way forwards (towards engine), meaning truck is now in 2H. Then I opened the non-OEM TCase actuator and spun the yellow gear into the 2H position (carefully look at the gear and set it to the position to where it can only spin in the direction to pull the rod outwards). The truck's 4wd switch works fine and im able to shift from 2H to 4H to 4lo with no issues except with the 4H. In 4LO the truck's front wheels lock fine.

I haven't replaced the TCase fluid yet so I'll update when I've done so to see if the issue persists.

Any advice on if I should open the TCase myself (side that faces the rear of truck) and order a specific part, or should I drop the whole TCase and replace it (don't really want to do because TCase assembly itself is like $3k).





Thanks,

Roger

 

You need to open up the transfer case or find a replacement. Sounds like your chain or chain sprockets may be wrecked and who knows what else has been taken out with it.

The fact that you get front wheel drive in LO makes no sense because nothing between the front and rear outputs changes in the 4HI to 4LO shift.

The only possible scenario is the front output shift collar somehow is not engaging fully in 4HI but is driven to engagement with the further shift to LO. If that's the issue then you need to open up the case to find the cause.

A good junkyard case can be had for a few hundred bucks and they're fairly easy to install and disassemble.