4x4 not engaging

Hey, I just bought my first taco and so far I love it. I bought it knowing the 4x4 didnt work, and now im trying to fix it. When I try to engage it, I know the hubs are locking, but when I shift into 4x4 the light on the dash doesnt come on, and the 4x4 doesn't engage. From all the research I have been able to do I think its a faulty solenoid on the diff, or maybe in the transfer case. I also found out that there is 3 different solenoid used for the 4x4 and it could be any one of them. Has anyone had this problem? and could you possibly lead me in the right direction for
A) finding the solenoid and
B) figuring out which one it is.

I am not positive that this is even the problem. Any help would be greatly appreciated.

Thanks

 

Heres an update on my problem. My mechanic and I spent a few hours trouble shooting the problem and we have determined that the switch is actually working fine. On the end of the switch is a ball bearing that when I shift into 4x4 is supposed to be depressed by something inside the transfer case. By sticking our finger in the switch hole we have figured out that whatever is supposed to make contact is not. What is actually making contact with the ball bearing we are unsure, but it seems that just fixing that problem still wont solve the 4x4 not engaging. Next step I think we will go into the transfer case, but this is going to increase the bill by quite a lot im sure.

If anyone can point us in the right direction to cut down on the time we spend trouble shooting I would really appreciate it.

Thanks

 

Thanks for the quick reply, those exploded views are awesome. Ill update after this coming weekend and let you know what we accomplish.

 

I have a similar truck with a similar problem and I'm trying to find out more myself. I have a 96 4x4 manual, and it will not engage into 4H when the lever is pulled. Nor does the light come on. I thought I'd ask a few questions to see how close we are.

Is your Transfer case manual shift or push button?

If manual shift, When shifting to 4H, does the shifter almost snap itself into the 4H location with very little effort? Almost pulling it into position?

I also just bought the truck. All i've done so far is pull up the dust covers on the top from within the cab and check that the lever is properly fitted. Next is the more intensive work which you are already starting. Thanks for any information, if its the same, perhaps two people with the same problem will do better than one!

 

My transfer case is manual shift. It does take very little effort to move the shifter into 4h yes. Next weekend we are taking the transfer case right out and digging in. We have no idea what we will find, but when we do I will post exactly what the problem was, cost of parts, and time it takes to fix. Maybe with that info it will help you with your problem.

 

Wondering why you have a non-Tacoma mechanic who doesn't know what to do...?

 

I have an excellent mechanic who is a friend but has never been in a tacoma transfer case. He has a friend that worked on Tacoma 4x4's for 8 years that is gonna come take a look once we have the transfer case out. I have thought about taking it to a 4x4 specialist but the cost of labour will be more than double.

 

Understand... best of luck to you... I am sure they will get it working so you can drive in the Canadian winter, eh?!!

 

This may or may not help, but it worked for me:

I was playing in a lot of mud and water when I first bought my truck. I had identical symptoms you originally posted about. There's a chance that your solenoid picked up moisture inside the housing and siezed (I use that word lightly, and here's why) the gears that assist with engaging 4H/4L. Those are little gears and it doesn't take much to gum up.

I could hear the electric motor on the front diff clicking when I shifted into 4H/4L. All I did (and this, no kidding, fixed it) was tap lightly on that motor's housing a few times with a ball peen hammer while someone in the cab was shifting in and out of 4WD. Lo and behold that little motor started making mechanical sounds again and my problem was fixed.

Hope it's as easy for you as it was for me.

 

Thanks Havoc, but CheyneMackie and I both have 96's which I don't think have a solenoid in the diff. We have manual style locking hubs.

Cheyne, I've been looking over the FSM and I'm predicting I've got a broken shift fork(or the rod the fork is on) that engages the gear that drives the transfer chain. In a couple weeks, my brother and I are going to drop the case and try to open only the back where the shift forks are. Then play it by ear from there... any luck on your end?

 

Solved!!! Atleast for me...

Dropped the case and pulled it open.

My going in Theory was that is was something to do with the shift fork or shift rod associated to the engagement of the Chain to drive the front wheels. This is due to its shifting behavior.

My theory was correct, we took the case apart from the back, not the front. (Took off the speedo gear shroud, then took off the entire backplate). From there I could see that the Fork was not broken, but was not where it was supposed to be. The result, there is a very tiny Pressure Pin which locks the fork stop into place. It had bent and fell out... and I found it in the bottom of the case.

Probably a $0.05 part... But I had also had to buy new gasket stuff, new quart of gear oil, and some time. Took about 4 hours total. All in all, happy with the low cost.

Tools needed... Sockets, long extensions, torque wrench, Phillips screwdriver, pry-bar, punches, hammer, Snap-ring pliers, Allen Keys, Jack/Hoist, RTV sealant.

A tip for those attempting to drop the Tranfer... it was REALLY easy to use a cherry picker from inside the cab and bolt it to the case to drop and re-install it. Easier than a jack from below. Be sure to have enough slack in the chain to go all the way up and down.