4wd System Operation & Help Thread

I’m confusing myself because I’m thinking I’m just testing one of the harnesses but according to my harness colors. Id be using both harness to get all wires tested for the chart test.

 

Ok thanks for that clarification. Here is a revised test for 2-4 and LO. Readings are good which means switch is working properly

 

Ok in that case it looks like the problem is going to be in the Transfer Case Actuator, so you are indeed seeing 0.13v on TL2 and TL3 with the switch in 4H?

 

In 4H I am now getting: .02V on TL2
13.37V on TL3

 

That's interesting, did any of the others change?

 

I stand corrected I just probed TL2 at 13.4V.

I am sorry. I’m trying not to force the pin in there so much. But this time I was frustrated so I pushed it ins little harder. And it read 13.4V

 

No problem, so it looks like the Transfer Case Actuator is not moving.
Have you looked at the actuator to see if the vent hose is attached?

 

So now I went to prob TL1,TL2, and TL3 on 4LO I was reading .03 V for all three….I thought that was odd so I went back to 4H to see if I would get the same readings when previously tested which was 13V for TL1, TL2, and TL3. But now there are reading .03V TL1 and TL2. And TL3 is 12.48V.

 

Something isn't right there, have you crawled under the truck and checked out the Transfer Case Actuator?

 

Checked tcase actuator. End of line is a little but no tears or rips. Held it by hand to see if actuator would move. Turned truck on, switched to 4H. I felt and head actuator move. Checked 4H light, still blinking no beeping. Switched to 4LO, no movement in actuator light still flashing. Put it into 2WD drive. Shut truck off. Turned truck
Back on, switch to 4H no movement in actuator light still flashing. Seems the actuator is intermittent, and will only ave movement when switching from 2H to 4H.

 

Little brittle**** @Dm93

 

Vent hose

 

I think the next step is to open the actuator and check the contacts inside based on the inconsistent voltages your seeing on TL1 2 & 3 just take care to not pull the main gear out without noting the position of it so you don't lose the timing.

 

Will pull out tomorrow. Any advice or tips tricks to pull out without pulling main gear.?

 

Yea they all kinda look like that on the end.

Hopefully those bolts come out, they look pretty rusty.

 

Perks of living in HI. Lol

 

I haven't had to take one apart yet but all I can say is when removing the cover try to keep the gear in place.

 

Update on contact points of transfer case actuator.

 

Might need to clean that up a bit, hard to tell if the contact track is worn down or if that's corrosion.

 

It’s some kind of grease. I figured that’s how it supposed to be. Cleaned every thing and put it back. Turned struck on and it switched to 4 hi and locked in. Went to 4LO and it flashed and beeped. Went back to 4H and nothing. Could definitely hear actuator working. But now just flashing again no beeping. Could the timing be off?