Transfer Case Actuator Changeout 2008 Tacoma

Hi. Been a while since I posted on here so I'm a little rusty. Oh, and happy July 4th!

Got a 2008 (second gen) toyota tacoma 4wd V6. Problem was 4x4 was intermittent (especially in wet weather) and unreliable at times going from 2wd to 4wd. Did that for about a couple years but then all of a sudden, now it's stuck in 4wd. Read all the posts about the front ADD actuator and I assumed that was it. Took the front actuator off and inspected it. Very clean inside, tested the motor and it works, soldered the connectors anyway, and put back together correctly. I did not orient the sleeve inside to the unlocked position and left it in 4wd. I am sure the vehicle is locked in 4wd.

Next, went to the Transfer Case actuator. Saw the vent tube was broken and I suspected moisture. tried tapping the actuator lightly with a rubber mallet and the plastic now 13 year old vent hose nipple broke off. So, I went ahead and removed the actuator and immediately saw the problem. Water inside, very badly corroded terminals, so basically a bad actuator beyond repair. Watched the repair videos and it is shot. Ordered a new actuator for about $250 off Amazon. The new actuator comes with a shaft attached that I plan on removing so I don't have to open the transfer case. I read it can't be removed without opening the transfer case.

My question is this: How do I orient (within the free play in and out) the transfer case shaft to reinstall the new actuator? I also am not sure what position the new actuator comes in - 2wd, 4h, or 4L? My old actuator was in 4WD position when taken off and the shaft was in 4wd since it was locked in 4wd. The front add is still locked into 4WD (I did not change the fork position). Should I take apart the new rear actuator and turn the gear to the 4WD position and then the new actuator will be in the same position as the old one? Or do I try to push the axle into the TC to the 2wd position (all the way in) and install the new actuator? I believe it is not possible to push the shaft into 2wd on this year tacoma. If I do that, i would think I have to align the gear position to 2wd? Also, there's about 5/16" of play in the shaft. How do you make sure the shaft is positioned (regarding the teeth) correctly when you put the new actuator on and slip the small round gear in? Watched and read a lot and can't quite find the answer. Thanks for any input!

 

While I’ve never timed the actuator.
There is a diagram in the link below.
It’s the picture at the bottom of the 1st post.
https://www.tacomaworld.com/threads/4wd-system-help-and-information.696298/