2005 Stuck in four low

Hah. I work on bikes too. Ever try to adjust the valves on a KTM 990? Rebuilding an actuator is at least 6 beers easier than that. When you pull the plastic case off there is about 3/4" of room before the clock spring comes loose on ya. Just look up in there with a flashlight and have a flat screwdriver ready to slide it onto the case if it sticks to the metal side, you'll see. Seriously under five minutes I could have you driving again. Then just leave it unplugged and mess with it at your leisure.

 

Do the 2 acuators work in sequence? Aka, does the ADD get its orders from the Tcase , or vise versa? What I am getting at is, if one is stuck , can tht keep the other from disengaging?

 

Not yet....have a quick link? So this is a common issue im guessing.

 

For the record , there is not much to the transfer case either . Removal , tear down and re-assembly is fairly straight forward .

 

Pulledd the black plastic cover off the tcase acuator... i am now in 2wd. Took the add off and manually unlocked the diff. Opened the add and it looks brand new inside. Soldered anyway ... Still not working correctly

 

See, told ya. Look inside the black plastic case on the t-case. It has three chrome strips the contacts on the back of the white plastic gear ride one. These get pitted from the water in there. Did you see any foamy white oil in the T-case actuator?

 

No water in any of the parts. It all looks new inside. Well, untill I dicked it all up. I dont think it was the actuators... Dealer says yes... Who am I to argue? Put power to the elec motor posts on the add, and the little motor spun.

 

Bring it to another dealer.... and trade up to a new tacoma!

 

Don't give up yet, it's nothing that you can't fix. Look closely at the contacts...clean them well with a toothbrush and some electrical contact cleaner. Make sure they are making a connection and not bent (check with ohm meter). You can always plug the ADD in and test it without actually having it installed in the axle. Worst case scenario buy a new front actuator and if that isn't it resell it here. Then move on to the Tcase actuator. Obviously there is demand for them lol. I'm sure you have checked your 4wd fuse by now of course, but have to ask...

 

I did pug the ADD in and let it dangle while turning the switch...nothing happened. But the timing is going to be off on the Tcase actuator now that I pilled the cover , then pulled the internal rod. I am going to go back to the Tcase today when I get home.....

 

Nightmare. Whats the offficial name or part number for the Tcase acuator?

 

might need a new ADD... thats what I needed in my 2004

 

this might sound crazy to you but if you have floor mats pull it back so that its out from under the clutch pedal an turn the switch to 4 low mine 05 has the same problem an I've tried everything people have said on here an nothing has helped until I pulled the mat back so the clutch would go COMPLETELY to the floor an it went right in... Hope that helps

 

i pulled mine off and did this to get it back to 2 hi there is a spring but wont make a mess. just have to get the gear put back in the right place. i just stuck mine back together and left it unplugged. i am going to take it back apart today and see if i can fix it right. but at least i can drive it in 2 hi now

 

I took mine apart also. But I can’t figure out the right position the 3 contact points need to be set at with the other side of it. You have any info? On which setting is for 2HI, 4HI, 4LO? I have been having trouble with my 4wd. But we figured out that it was the front ADD Actuator and fixed it. But before that we took apart the transfer case actuator and put it back together but the contact points are set wrong so it’s all out of sequence. Switch, ADD actuator and transfer case is all set to 2HI but the actuator is off.. I need it to be set in 2HI so everything can work properly again lol

 

How did this play out? Hope I’m not opening old wounds?

 

When trying to get out of 4WL, be sure to engage the emergency brake, and put that clutch pedal to the metal.