4WD not engaging and light not working

It's understandable for you to think that because your 96 works one way that others must surely be the same, but the difference between the two systems is documented throughout the forums and elsewhere.

 

Ok. Here to update. Replaced the 4wd transfer case switch (5 minute job) and no changes. I can still hear the relay click but no light at all, no actuator sounds, and no 4wd connection. Is it time to replace the whole actuator or should I look at something like the 4wd ECU?

Also, from what I understand, the 01-04s don't have any vacuum lines. I'll try cleaning the connections before I order more parts, but just wondering what my next step should be.

 

Did you rule out #1-5?



Post#3 on the previous page has the info you need to test your actuator.

 

Ok I found the problem lol. For anyone referencing this thread, be sure to pull your transfer case actuator covers.

 

Update:

Cleaned everything up and knocked some rust off the contacts while I was at it. Added some dielectric grease and reinstalled. It took a few tries and some taps on the actuator, but it's working again and the 4wd light turns on and off as normal. No clue how that much dirt and sand got in it, but I made sure to clean up the gasket and also grease it.

I did get some popping from the front end shortly after engaging 4wd. It seemed rather random, but I think it is from the ADD skipping/trying to lock up the front end. It's happening less frequently the more I drive it so I'll chalk it up to not being lubed/warmed up in a while. Something to keep an eye on though.

 

Final update:

Took the tacoma offroad for a day and the 4wd got plenty of use and performed flawlessly. No more weird bangs or pops to date.

Thanks to everyone for the input and advice.