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Old 01-05-2015, 11:08 PM #1
CaptCaveman CaptCaveman is offline
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4WD Actuator Stuck

I have a 2001 4Runner Limited with a stuck actuator that my dealer wants to charge me $2700+ to replace. I found the part at NAPA for $330. So the only question I have is can I replace the part myself? Anyone know of a YouTube video or detailed instructions I can use? I REALLY don't want to pay that much money for this. Any help is appreciated.
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Old 01-06-2015, 04:33 AM #2
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Quote:
Originally Posted by CaptCaveman View Post
I have a 2001 4Runner Limited with a stuck actuator that my dealer wants to charge me $2700+ to replace. I found the part at NAPA for $330. So the only question I have is can I replace the part myself? Anyone know of a YouTube video or detailed instructions I can use? I REALLY don't want to pay that much money for this. Any help is appreciated.
First you need to specify if front diff actuator or T-case actuator. Two different things--both could be called 4wd actuator.
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Old 01-06-2015, 11:44 AM #3
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What are your symptoms?
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Old 01-06-2015, 04:50 PM #4
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THere are two vacuum lines from the diff that go to a small vacuum distributor (forgot the real name). It's located under the hood in back of the battery on the hump of the drivers side wheel well.

Switch the lines and it will realease the acutator. I did this and it worked for me, then I switched the lines back to the original spot.

A toyota mechanic had previously told me I need a new transfer case and he'd put one in for about $2,800. 5 years later everything is working fine.
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Old 01-06-2015, 05:08 PM #5
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Quote:
Originally Posted by potomacduck View Post
THere are two vacuum lines from the diff that go to a small vacuum distributor (forgot the real name). It's located under the hood in back of the battery on the hump of the drivers side wheel well.

Switch the lines and it will realease the acutator. I did this and it worked for me, then I switched the lines back to the original spot.

A toyota mechanic had previously told me I need a new transfer case and he'd put one in for about $2,800. 5 years later everything is working fine.
He has a 2001. Front diff has electric actuator in ´01 and ´02. No vacuum lines to front diff. No VSV´s (Vacuum Switching Valves--the ¨real name¨) on driver side fender wall.
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Old 01-06-2015, 06:13 PM #6
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First you need to specify if front diff actuator or T-case actuator. Two different things--both could be called 4wd actuator.
Don't confuse him with facts.
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Old 01-09-2015, 12:15 AM #7
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I really appreciate everyone's feedback and advice. As it turns out I was able to Disengage the actuator manually. Simply removed the actuator cover (3 screws) and turned the gear wheel. Put the cover back on and voila, fixed. The thing is the Toyota dealer told that that it was impossible to disengage and would need to be replace at a cost of $2700. Suffice it to say I won't be going there again.
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Old 01-09-2015, 06:49 AM #8
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Quote:
Originally Posted by CaptCaveman View Post
I really appreciate everyone's feedback and advice. As it turns out I was able to Disengage the actuator manually. Simply removed the actuator cover (3 screws) and turned the gear wheel. Put the cover back on and voila, fixed. The thing is the Toyota dealer told that that it was impossible to disengage and would need to be replace at a cost of $2700. Suffice it to say I won't be going there again.

Looking at the age of mechanics in my local dealership. Half may have never saw a 3rd gen. My neighbors kid went to auto mechanics school in Williamsport PA. Was not impressed. I shown him how to set points in his dad's TBird, work on the Holley Carb on the truck he just bought and get his 84 Camero with the crossfire injection on it. He said the tore apart and rebuilt a GM V6 and 700R4.

Scan tools and component replacement is what their all about.
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Old 01-09-2015, 10:50 AM #9
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Quote:
Originally Posted by CaptCaveman View Post
I really appreciate everyone's feedback and advice. As it turns out I was able to Disengage the actuator manually. Simply removed the actuator cover (3 screws) and turned the gear wheel. Put the cover back on and voila, fixed. The thing is the Toyota dealer told that that it was impossible to disengage and would need to be replace at a cost of $2700. Suffice it to say I won't be going there again.
Dealers are THIEVES, all of them.

So, does this mean you can shift into and out of 4wd with ease? If not try right hand turns just after you depress the 4wd button and left when disengaging. That worked for me, would engage within seconds of the turn, took several times but eventually it engaged without the turns on demand. Woohoo!
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Old 04-13-2020, 08:07 AM #10
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Quote:
Originally Posted by CaptCaveman View Post
I really appreciate everyone's feedback and advice. As it turns out I was able to Disengage the actuator manually. Simply removed the actuator cover (3 screws) and turned the gear wheel. Put the cover back on and voila, fixed. The thing is the Toyota dealer told that that it was impossible to disengage and would need to be replace at a cost of $2700. Suffice it to say I won't be going there again.
Can you explain this process a little further
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Old 04-13-2020, 04:58 PM #11
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Can you explain this process a little further
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Old 10-18-2021, 11:14 PM #12
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3rd gen 1999 rear transfer case actuator

I had to clean my rear transfer case actuator on my 1999 limited. It is now working….. I need to know the correct the position / timing of the actuator gear. I have looked around this site for a while and there is conflicting information on where to place the gear. In relation to the notch in the housing….Should the transfer case be in neutral or in 2WD when I install the actuator motor? I placed in back onto the 4runner and when I click the 4WD button it pulled the transfer case out of gear and I can utilize any gears no forward reverse etc. obviously the gear timing is off just looking for a little help.
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Old 10-24-2021, 04:26 PM #13
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Actuator gear

Did you ever get an answer regarding the timing of the 4WD actuator gear?
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