How To Trouble Shoot 4x4 Actuator

Replaced actuator dec 17 now again no 4x4 light. About 2 weeks ago a jump in truck start it and the light is flashing. This after spending a bunch of $ on all new bilstein 5100’s pads and ,rotors ,bushings Where should I start? Anyone have problems with rock auto front dif actuator part number 8501.10.0029 ? Any info would be great. Thanks

 

was there a write up or link on this? i'm interested...

 

I still got no 4x4 after my mechanic spent hours testing stuff. Apparently there is no power going to the actuator. Anyone else have this problem or suggestions on where to look or test ?

 

I’m having the same issue. Got stuck in 4h. Then shut the truck off and the lights never worked again but was stuck in 4h still. I replaced t-case and it got the lights working as they should but still not engaging. Thinking it was the front , I replaced it as well..... still nothing. The lights are working as they should now (flashing) but the Tcase isn’t sending signal to the front telling it to lock in 4h. Since it won’t go 4h it obviously won’t go 4L.

I can’t figure it out. Has to be a wiring issue or a fuse or a sensor. I will look into it more in the morning

At the point of getting just manual conversion

 

sub might need this.

 

My truck surprisingly engaged into 4x4 today. After 2 weeks of nothing. No light, no beep. Nada.

I am thinking the same issue may be something electrical or a sensor.

 

Been struggling to get my 05 out of 4HI after trying to test 4LO on the street. Eventually had to unbolt the front actuator and physically disengage the front diff by hand. Front actuator works fine hooked up to 12V. Also thinking its the 4WD ECU or transfer case actuator. Truck seems to be drive fine in the front disengaged but seems T-case is still engaged. Unfortunately I might have to take it to a dealer.

 

Anyone know where to buy the 4wd position sensors for the teansfer case actuator? Cant find them for the 2012

 

Quick rundown, 2002 tacoma, A/T, 4x4 button in shift lever. Truck has been sitting for about 2 years. Got the truck running, went to test the 4wd, no light on dash, no noise of it engaging, does not feel like the 4wd is engaged. Most of the feedback on the forums revolve around a flashing 4x4 light or some variation of that. Mine is doing NOTHING. I have tested the switch on the lever, tested that there is 12v at that switch, obviously the fuse is good. Im thinking i need to confirm the electrical system first before i started removing/ replacing parts. Any ideas?

 

I read somewhere where a guy had a similar problem and all he did was go to the actuator on the front differential and unplug the wire connector, clean it up a bit and reconnect it. His 4 wheel worked after that. I had a problem with my front actuator on my 2007 Tacoma not engaging. Replaced it before I found out that info. Took my old one apart and it was as clean as new on the inside. Did a bench test and it worked fine. So I probably just had a bad connection. Being your truck was sitting for two years I would try doing that before replacing parts. You may get lucky. Wish I tried that before replacing mine. Which wasn't exactly cheap or easy!

Aloha

 

Thats what i'm thinking. And certainly hoping, that its just an electrical issue. Everything was working fine when i parked it. Right now i'm looking for the best method to troubleshoot the connections.

 

Vehicle: 2006 Hilux (South Africa) 4.0 V6, 335,000km
Problems: No 4WD-Hi, front wheels not turning. Dash light was flashing initially (months ago), but more recently nothing.

1) Drained front diff oil;

2) Removed ADD unit (yes that top bolt is a nightmare)

3) Remove 5 screws (slow with pressure, they are tight)

4) Found 1/2 cup water ingress, rusted motor and contacts

5) Striped and cleaned everything (toothbrush, degreaser, carb cleaner) and tested motor with 12v supply. Motor was seized (rust).

6) As I had been doing rust repair on body panel using pool acid to eat rust, and thought needed a new ADD (can't get motor separately?!), thought I would try an acid bath on the motor and see if it would come loose... 2 min in pool acid, scrub with toothbrush, rinse with water, then spray inside (thru holes) with carb cleaner... and motor was able to turn again!

7) Applied 12v supply to motor contacts, confirmed working

8) Reassembled, but did not have any grease. Seal also stretched so cut and joined with gasket maker. Soldered motor contacts to ensure 100% connection.

9) Reinstall ADD, fill front diff oil (painfully tight fill location!)

10) Place gearbox in 4WD-Hi and 4WD-Lo and confirmed working (front wheels turn)... but no lights on dash

Anyone know what I need to do to fix dash light? Thinking one of the switches or contacts inside ADD wasn't right?

 

Looking for some assistance troubleshooting my transfer case actuator issue. I have a 2014 5 speed manual new to me with 50k miles and in excellent condition. Used 4 hi all spring in the snow with no issues.
Shifts in and out of 4 hi smooth as silk sitting or on the fly. Have verified front driveshaft is engaged.
Tried numerous times to put it in 4 lo and get the blinking light. Finally pushing hard on the switch numerous times from 4 hi it finally went into 4 lo. Is the switch supposed to push in from hi to low? Mine seams to to not push in but just turn.
Anyway when I got it into 4 lo it wouldn’t come out....just blinking. Tried everything to get it out but no luck. Pulled the plastic cover off the transfer case actuator and turned the gear to manually get it back into 2hi with success. I don’t think the guy before me ever put in 4 lo so I shifted it manually numerous times thinking it needed to be used a little. Seems to shift smoothly. Put it all back together and tried it again but got the same results. Had to push hard on the switch numerous times from 4hi to 4lo and got it to ingage, but ended up stuck in 4 lo again. Took it apart again and manually shifted it into 2hi. Tested 2 hi to 4 hi and no problem. Drives just fine.
Not sure if I have a bad switch,one of the sensors is bad, or the actuator itself is bad.
Any help would be appreciated.

 

Do you come to a stop and put the trans in neutral before shifting in or out of 4 low? That's how I do mine. 2007 Tacoma auto trans. On mine you have to push the switch in before going to 4 low or from 4 low to 4 high. I don't have too push my switch too hard so if you have to use a lot of pressure might be a bad switch. Try putting it into 4 high, after it engages come to a complete stop, put the trans in neutral, then put it into 4 low. To take it out do the opposite. Come to a stop, trans in neutral, switch to 4 hi, then if it disengages drive slowly and switch back to 2 wheel drive. Hope this helps.

Aloha

 

Followed all the steps that you mentioned without any luck.
Does the switch actually stop at 4 hi and require you to to push in to advance it.? I would assume that’s how it’s supposed to work as it says “Push” on the switch. Mine goes from 2 hi to 4 lo without having to push it in.
Two 4-Runners and a FJ with a shifter on the transfer case before the Tacoma so I’m not sure how it’s supposed to function.

 

Yes mine stops at 4 hi. then I stop the truck, put in neutral push in on the switch and rotate clockwise to 4 lo. I have 4 Tacomas in my yard. 2007,2011 and two 2018's. Haven't put the 2018 ones in 4 wheel yet. The others work the same. Used to have a 1999 that worked like the others. I did replace the actuator on my 2007 about 4 years ago. . Wouldn't go into 4 hi or lo at all. And that was only on the second time putting it into 4wd. Used my older trucks for all my 4 wheeling. Worked fine after that. Not sure what could be wrong with yours. If it goes into 4 hi don't think you have a connection problem. Could be a bad actuator or switch. I would hate to change the actuator and still have the same problem. Those things are a pain to replace and not cheap.
I also have a 1990 Toyota pickup (I'm the original owner) that has the old school 4wd. Put the stick in 4lo, go out and manually lock the hubs then go. Never ever failed! Kind of like the old style better. Good luck!

 

I did a quick search on you tube. Found a video that says on a manual trans you have to stop the truck push in the clutch before switching to 4lo. All my trucks have auto trans so I just go to neutral. Here's the videos I looked at:
https://youtu.be/MdJ2z3dx520
https://youtu.be/M9MjFyU1S2g

 

Got it fixed. Took the position sensors off of the actuator. They looked like new but I massaged them a bit thinking one may be stuck. Put the actuator back together and she went in and out of 4 lo smoothly, but this time I had the clutch in fully and foot on the brake. Tried 4 lo without foot on brake and it won’t go in and I get the blinking light. After cycling numerous times in and out of 2 hi, 4 hi, and 4 lo I discovered that that to get in and out of 4lo besides being in neutral with the clutch in, you must have your foot on the brake. I’m wondering now if that was the issue all along. Not sure if this just a 2014 thing or not. Anyway, everything is shifting smoothly.

 

Right on! Learned something new. Never knew about the brake thing. But since all my trucks are automatics I always have my foot on the brake when going from 4Hi to 4Lo. May try it without pressing the brake next time just to see what happens.

 

Good Day.
I figured I would chime in here and look for some help. I have been having the blinking light 4x4 and 4 low for almost 8 years!!!! While under warranty toyota replaced some parts and it would work for a while then I would bring it back when it started blinking again. I have always thought it was electrical because it started after washing or on slushy roads. Last year while camping it locked in with both flashing and wouldn't come out. after trying everything for a few days I pulled the Transfer case actuator and manually pushed rod back in. After driving for about 100km the front dif finally released. I worked on it a few times last fall, pulling front and transfer case actuators and cleaned and soldered. But was unable to fix the problem. WHen 4x4 H is selected I can hear the 4X4 ECU click and both front diff actuator and transfer case both seem to engage as designed. But lights start flashing and then the only way I can get out of 4x4 is crawling under and manually pushing rod back in. I deployed last winter so left it be while truck was in storage. Since my return a few weeks ago truck has been working good, and today was the day I had time to try 4x4 again. No luck!
I have it up on blocks today and yes 4x4 H is fully engaged, but lights both flash. I cant tell if 4x4 Low works or not as I am alone and cant tell the difference when up on blocks. I think that the mechanicals are all working, but the ECU is not getting the message and then puts into fail safe by flashing. Once in fail-safe I don't think that the selector switch will work. I think my problem is 1) plungers on transfer case rod not sending proper signal to 4X4 ECU, 2) bad ECU, 3) short in wire along the way since this has happened for years when wet, or lastly 4) bent rod in transfer case.
I am pretty good with following mechanical instructions but really suck when it comes to electrics.
I could replace the front ADD or transfer case actuator but I really dont think this is the problem. And no, I don't really want to pull that front actuator again. Sorry for the long story, but wanted to give as much info as possible so someone wouldn't tell me to read the visor or rock back and forth.