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Did I break my transfer case?

Discussion in '2nd Gen. Tacomas (2005-2015)' started by Macs05tacoma, Feb 10, 2020.

  1. Feb 10, 2020 at 5:36 PM
    #1
    Macs05tacoma

    Macs05tacoma [OP] New Member

    Joined:
    Feb 9, 2020
    Member:
    #318734
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    Gender:
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    First Name:
    Mac
    Hi, I bought a 2005 tacoma trd offroad with 135,000 miles a few months ago and recently have been struggling with an issue with the 4wd system; just looking for any information anyone may have relating to my particular situation. Here's what happened: I engaged 4HI at a near stop while coming out a large rut across a dirt road. I noticed a louder than normal clunk, but 4HI seemed to be engaged and I continued driving. Later, when I went to shift back into 2Hi, all I got was the flashing yellow/green 4x4 light on the dash flashing constantly. I messed around with the switch on the dash and couldn't make the shift into 2Hi so I left the switch in 2Hi and after a few miles on the highway the light went off as it normally would in 2 wheel drive. After arriving home I tested that I was indeed in 2wd and tried to switch back in to 4Hi; the 4wd indicator light went back to flashing and has been in 2wd with the flashing yellow light since. I am by no means a mechanic, but I like doing work on my vehicles myself, so after some extensive research online, I proceeded to check all of the common problems; I tested the dash switch and all of the connections to the a.d.d. and transfer case actuators, then opened up the a.d.d. actuator (the one on the front diff) and found and replaced a broken plastic gear with a part from a junkyard. Tested it and it seemed to be working properly, so I reinstalled it, making sure everything was lined up properly. Excited that I had fixed what I thought was my issue, I started the truck and now I still have the yellow 4x4 light and now the orange 4lo light is also flashing. Makes me wonder if that means I screwed something with that actuator? Next I decided to remove the transfer case actuator and test that it worked. I had read on another forum post that it was possibly to shift the transfer case manually so while the actuator was still off I tried to see if I could manually shift into 4Hi and 4Lo by pushing in the shift rod that the actuator attaches onto (pretty sure it is all the way out; I'll attach a picture of it) and I can't budge the shift rod at all. That's basically where I'm at right now. Should I really be able to manually shift that way or is there something seriously wrong inside of my t-case? This is with the wheels on the ground and the parking brake on. I applied quite a bit of force against the shift rod with a block of wood. At a bit of a standstill in deciding what to do next. Really appreciate any feedback

    20200207_182540.jpg
     
  2. Feb 10, 2020 at 5:39 PM
    #2
    Muddycoinwash

    Muddycoinwash Well-Known Member

    Joined:
    Dec 20, 2019
    Member:
    #313803
    Messages:
    154
    Gender:
    Male
    Vehicle:
    2015 TRD OR access, 2000 4x4 reg
    Welcome to TW, best of luck!
     
  3. Feb 10, 2020 at 6:07 PM
    #3
    Marshall R

    Marshall R Well-Known Member

    Joined:
    May 28, 2015
    Member:
    #156224
    Messages:
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    Gender:
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    First Name:
    Marshall
    Vehicle:
    07 White TRD double cab
    none
    I don't think you broke anything. With a 15 year old truck parts will wear out and I'm thinking you may just need to figure out what needs to be replaced. You may need to take it to a mechanic who knows what he is doing.

    And next time breaking things up into a few paragraphs makes it a LOT easier to read.
     

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