4WD actuator not working

Well guys.... when it rains it pours I was heading into work today and i usually engage 4WD for about 10 miles every month. While driving i engage 4WD and everything engaged smoothly. When i went to disengage it the 4WD light stayed on. I finally got it to go out by constantly shifting the lever in and out of 4WD. Now when i shift into 4WD the light wont come on at all and will not fully engage into 4WD??? So when i got home i jacked one of the front wheels up off the ground and shifted it in to 4WD. I hear a click under the dash on the passenger side, the transfer case engages, but the front ADD will not actuate and the 4WD light will not come on. Everything looks ok and everything is connected and in place. I even unplugged the 6 pin connector from the actuator and plugged it back in and still nothing. I also tried taking a wrench and tapping the actuator, still nothing.

So my theory is that my actuator motor took a shit on me... cuss everything else seems to be working except the actuator. Where can i find one at a reasonable price and PLEASE dont tell me that i have to go to the dealership. Also what causes these to stop working? I only have 101000 miles on my truck.

I should also add that i have the shift type 4WD lever (no button). And i only have one vacuum line which is only a breather tube going to the actuator. The rest is electronic.

 

Have a peek at this guys post . See the switch on the top of the transfer case ? take it off and make sure it isnt stuck . He has the electronic transfer case and you have a manual shift but they still use the same switch to get the front actuator locked into 4x4

http://www.tacomaworld.com/forum/technical-chat/325972-toyota-transfer-case.html#post8555026

 

The only thing is i have no actuator on my transfer case. If i still have this switch on my transfer case but no actuator, where would this switch or sensor be located. Also i have no vacuum lines on my front diff actuator, just a breather hose to the actuator and then the 6 pin electrical connector.

 

I had the same actuator go out on me. The breather tube that you are talking about was cut off some how and the actuator became full of water and mud. Kinda a small hole so I'm surprised that so much gathered in there.

The only difference with when my actuator went out, the 4wd indicator light would blink because it was detecting an error. If you are not getting any light, you might have more wrong. Granted I'm not a mechanic so my word shouldn't hold much weight.

If you wanna compare, I would switch my truck from 2hi to 4hi and I would get the blinking light. The transfer case engaged judging by the front drive shaft spinning then it would just keep trying. Sometimes I could trick it into engaging by turning my truck on and off.

(Edit: Mine is a 2007 so that may be the reason for the light difference. I can tell you that the actuator is stupid easy to change out. Breath tube, plug, 4 bolts and some RTV. Just be ready to catch some diff fluid and make sure you check your diff fluid afterward.)

 

I have one for sale if anyone needs one? Pm me

 

Just a thought hear... Is it possible to possibly disassemble the unit and clean the contacts? Or is the actuator a unit that once its done its done?

 

There's a thread somewhere on here that talks about taking apart the actuator and soldering the contacts.

 

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

 

Ok.... So i purchased the actuator at a wopping $316.00 , not happy about that. I opened the actuator up the other day and everything look clean??? Theres no water or mud and theres still electrical grease in there. I did do some minor diagnostics the other day. When i shift the 4WD lever i hear a clicking noise behind the passenger side kick panel, which im assuming is the 4wd relay. So the relay is getting juice to tell the actuator to engage. To confirm this i got under the truck and with the lever still in 4WD i unplugged the 6 pin connector from the actuator and i could hear the relay click off, i reconnected it and i herd the relay click again.... So my theory is that the actuator is getting juice. I also did the same thing on the transfer case switch that screws to the upper passenger side of the case and when i unplugged and plugged it back in i could hear the relay click on and off.

After reading my diagnosis would you agree that it is in fact the actuator not engaging???

 

Just an update.... i got the new actuator in yesterday and everything is back to normal. Still mind blowing that the old actuator went out like that, but im going to keep it and mess around with it to see if i can get it working again.

Thanks for all the help!!!

 

My 4wd went out on me the other day wheels were slipping when turned on didnt think about it and turned dial to 4H. Big No-No! Now its eff'd up and wont go in 4Hi or 4Lo and when its in 2Hi green light still blinks saying its in 4wd. Took it to dealership because they said was prob actuator over phone and was covered in power train warranty (I'm at 44K milage) but dropped off they said it was actuator and its electrical so its not under powertrain and im passed bumper to bumper 36K warranty! Said be $2,200+ to fix cause gotta drop transfer case and actuator is over $1,100 for part. Im gonna pick it up and drive in 2WD till find better(cheaper) place to fix-im not very handy with the steel if ya know what i mean