Front Wheels no Engaging when 4WD is On

Just finished installing a new clamshell with 4.10s from ECGS. When I engage 4wd it appears to engage just fine. 4wd light lights up and I hear an actuator. However have all 4 corners of the truck off the ground and front wheels are not spinning. ADD actuator is plugged in, along with vacuum line. Although from what I understand vacuum line doesn't matter, just a vent.

 

Is the front driveshaft turning? Yes, then problem with ADD or in the front. No, then transfer case not engaged.

 

Front drive shaft is turning. Tip diff down and take add apart? Any way to check with Techstream?

 

If it worked before. I'd start with a thorough check to make sure everything is correctly connected and nothing was pinched, etc. Then, I'd look at the ADD to hear if it's moving when power is applied.

 

Can't tell from the video. Does it sound like this? Will have to have a buddy come switch into 4wd while I'm under it.

Uploading video in a moment.

 

Actuator is actuating. Any other ideas on what it could be? Possibly something with CVs?

 

My guess is that there's something not aligned correctly or came off which isn't locking the front axle. I've never had the Toyota version apart (yet) but if its like all the others, there's a fork or collar that slides back and forth to lock the front.

 

If the tcase is actuating and the front driveshaft is spinning, there's probably a broken CV

 

/thread

 

Wait, you are only testing with all 4 wheels off the ground? Try this.

Leave the truck turned off. Go to one of the front wheels and turn it by hand. Whichever direction it spins the opposite side should spin the opposite direction. If it does, then you are working fine. If one wheel spins and the other does nothing then you are not engaged.

I have a feeling you are engaged just fine and your problem is that you are lifted off of the ground

 

Yes, trying to diagnose the specific problem.

Thanks, tried that but turning the wheel by hand I do not get the other wheel turning the opposite way. Possible that the CV came apart inside the boot and I didn't notice upon install? Assuming 4wd would still engage and make a horrible noise?

Also how much of a gap should there be between CV and Diff? The CV dust cover is sitting right inside the lip of the diff but there is a slight gap on both sides where CV enters diff. Assume that's normal, but truly don't remember if it was completely flush or if there was a small gap.

 

Take a picture of the gap. There is a tiny one, maybe less than an 1/8

Did you feel the cv snap ring pop in when you hammered it in?

 

Can't say I felt a true snap, I'll take a pic.

 

Pics attached:

Passenger Side




Drivers Side

 

Dropped diff down, pulled ADD. Looks great and tests out for OHMS. However when sliding the collar inside the diff manually I'm still not getting the front to engage.

 

So with the add off and the collar manually slid over you still don't get the front engaged? When you swapped over the Diff tube did the Diff already have the little stub gear on it? Couple people in another thread said they didn't have it and had to move it over also.

 

Pretty sure it did, I can see a gear that the collar is sliding over. I'll snap a shot of the old diff and pull up the pdf blowup of the diff.

 

FUCK! You might be right.