Stuck in 4L, transfer case actuator spur gear would not budge

Thank you everyone for your feedback and sharing your experiences as well as knowledge!

I had some time today so I was able to get the TC actuator rod moving back and forth between H2 and H4 by hand.

Per Dm93's suggestion, I was also able to rotate the big gear back and forth between H2 and H4 by hand.

With that said, L4 is still no go.

Put everything back together, still no H4 as the green 4WD light just flashes.

I think the next step for me is to put 12v leads on the actuator motor to see if it's actually working??

I'm hoping all that initial grinding issue didn't destroy it too.

Also, remember when it was stuck in L4, all wheels spins freely except for the front passenger wheel. It spun very slowly and jittery like the seconds hand on a clock, just tick tock tick tock...

Do you think that contributed to the current H4 issue?

Last but not least, what about the front diff ADD, do I need to pull it to make sure the collar is in the right spot?

Thank you all again, knowledge is good!

 

Did you verify timing of the gear?

If so I'd want to check limit switch voltages before exploring any further to see where we stand.

 

Thanks again everyone! H4 issue solved as I got my hands on another actuator motor.

Dm93,

The timing is correct. Didn't check limit switch voltages because I got my hand on another actuator motor.

During a family gathering, found out that a relative has an actuator laying around because he replaced it a few years ago due to water damage. He was able to clean up the water damaged one and held on to it as a back up. He gave me that back up actuator and took the one on my Taco with him so he can try to fix it since he's done it before.

Anyways, after I installed his back up actuator on my Taco, H4 is working again. I didn't want to chance trying L4 because I think it's already gone due to the initial grinding issue that started all. I also don't want to break the actuator motor again. I use H2 and H4 like 99.9% of the time anyways so L4 can wait til I do the transfer case swapped down the road. As stated, I have not used L4 in years and that's probably why it's bound up now.

I was able to answer my own questions:

1. Didn't have to remove the front diff ADD and move the collar.
2. The front passenger side wheel spends just as fast as the other wheels once I stepped on the gas pedal. However, since it spends much slower than the other 3 wheels in first gear without pressing the gas pedal, I may have to do some research on it. Perhaps, the bearings are more worn?

What do you guys think why that wheel is more sticky than the other 3 during free spin in first gear?

 

The end game for me is still a TC swap or FJ TC swap down the road so here's another question.

I don't think it matters but want to double check with you all first since you have more knowledge about it than me.

Does it matter if the used TC comes from an automatic Gen 2 Taco even though my Taco has a 6-speed manual tranny?

I asked because I did some research on used Gen 2 Taco TC and some of the inquiry forms asked if the transmission on my Taco is an auto or a manual.

TIA!

 

I believe the spline count on the output shaft is different between the manual and auto trans.

 

Thank you, will try to confirm that when it's time to purchase a TC.

 

Where are you located? Ive got my stock tcase for sale after I just did the FJ transfer case swap

 

This thread may be of use to you when it comes time.
Alot of links there.
https://www.tacomaworld.com/threads...-4-wheel-drive-or-automatic-to-manual.702733/

 

@Strictlytoyz might know this

also, here's the thread for the FJ tcase swap:
https://www.tacomaworld.com/threads/lets-see-your-fj-case-swap.455278/

 

Not barrage your thread with my FS posts, but you may need this if you're planning on deleting the front diff ADD too:

https://www.tacomaworld.com/threads/fs-fj-cruiser-front-diff-tube.844003/

 

All good and thank you FF2, knowledge is good!

 

Manual is 22 spline, 23 in the auto. You can swap your current input shaft into an auto case if you find one.

 

Thank you!

 

You'll also need to change the ring gears if you go the swap route

 

I imagine since there are a lot fewer 6-speed manual than auto, it'll be harder to find a manual tranny TC.

Does any of you know how many other Toyota models share the same exact TC with the Gen 2 Taco? Tundra? 4Runner? Lexus??

Since there's not many used 6-speed TC out there per my research, the more options available from other models the better just in case I want to do a direct swap without any mods, swapping internal parts and/or adding additional parts to make it work.

Thanks!