2002 Limited

I’ve searched all over and I can’t find an answer to this problem.

Background: I’ve had an ongoing problem with my 4WD which I’ve come to think is due to the TC actuator. I’ve tested the obvious stuff - fuse, 4WD button, 4WD switches on the side of the TC, front diff actuator. The TC actuator seems to be sticking: not working when I push the button, as well as randomly activating 4WD and/or center diff lock. The breather tube is missing, and I think I got some water in there during a few stream crossings over the summer. I recently got it engaged by hitting it with a hammer.

I’ve read a lot of reports of people opening these things up and having a cup of water pour out. I’m thinking I might see the same. I was hoping to either clean it up if it’s salvageable or swap it with a junkyard part. My problem is that all the videos and write ups I’ve found suggest you have to remove the access plate and pull the gear before pulling the actuator off. My actuator has no access plate. See picture below (mine on the left, one with an access plate on the right).



I suppose I could pull the plastic actuator cover off, but I read there are some springs in there you have to be careful with, and I’d much rather do it on a work bench than upside down while parked on the street.

Questions:
- Is there a way to pull the actuator without pulling and disassembling the TC?
- If I can remove it, does any know what else besides an 01 and 02 4Runner shares this part? I think some Tundras, Sequoias, and Tacos do, but I’m not sure what years.
- If I can’t remove it, what’s the best path forward? Swap the TC with one from a junkyard? Take off the plastic cover and hope for the best? I've read these sort of repairs run about 2k from the dealer and that's not really an option.

Thanks all!

I am also having tcase actuator issues, but in my '00 multimode case. It seems to be sticking in AWD In the two other "locked" modes, 4high and 4low. Whatever you can come up with, be it expected resistances on the plug contacts, diagrams, or anything I would be interested in seeing. Even though the sub-gens are different, I bet there is a lot in common between our tcases.

There's some overlap. There's a ton of info on this thread:

4WD won't disengage on 99 4Runner LTD - Page 28 - YotaTech Forums

There's a few differences between 99-00 Multimode and 01-02: Yours is vacuum activated, mine is electronic. Yours is 4 pin, mine is 6. Your front diff actuator has a removable sensor, mine is integrated into the actuator. You can easily pull your TC actuator, and based on the lack of responses to this thread, I don't think I can pull mine. You have an ADD relay, mine doesn't.

Here's what I would suggest:

- Check your ADD relay.

- Pull the 4WD sensors on the back of the T-case and check for continuity, there's a good video here.

- Also pull the sensor on the front diff and check that.

- Try and activate both actuators via the vacuum tubes. If they work fine, your problem is likely upstream (in the VSV or somewhere in your electronics).

- check to make sure the 4WD switch on your shifter is working correctly (via continuity test.)

Other possible problems:

There are two sensors on the top of the TC, one for 4L and one for neutral. I'm not sure what sort of issues they cause, but you need to drop the TC to access them, so I haven't looked into that yet.

A lot of people have issues with the TC actuator - might be worth it to pull it and check for corrosion and water damage. There's some debate about "timing" when reassembling, I'd do a lot of research before taking that apart.

A fair number of people have said the ADD actuator went bad. That part is $300 new, but I got one for $20 last week at the junk yard.

more info here:

How To Trouble Shoot 4x4 Actuator | Tacoma World

Was there ever an answer for how to remove this actuator? I have the same problem...no access panel on the back of the actuator. Any help is very appreciated!

Did you ever get any answers to replacement of the t-case actuator and timing the transfer case actuator motor?

I have not seen a response or solution yet. Would love it if someone has one to post.

I have a 2002 4runner Limited. This (01 and 02) transfer case actuator is NOT removable. You can pull apart the actuator (like I regret doing-- mine was not going into 4x4 and was having to tap with a hammer, thought is was dirty, so I pulled it apart, the little motor on the plastic cover was trying to go into 4x4, but something was keeping the gear from turning into 4x4, so when I pulled the cover w/motor on it, it sprung the cover about 1/4 turn or so... NOT good). IF you decide to pull this apart, make damn sure your 4x4 button is not pressed). The gear is timed to specific spots/elect contacts, so pulling that off is a gamble too). If you're having to tap this guy to get it into 4x4, I would just DEAL with it and keep a small hammer around.

Yesterday, I replaced my entire transfer case (cheaper and easier to replace than the actuator by itself)... still stuck in 4x4 with blinking dash lights and zero signs of clicking/unengaging when I unclick the 4x4 button. The physical 4x4 lever only gives options for 4L, N, 4H... the unpressed button makes the actuator put the TC into 2wd, which mine is not moving. Next step is to test my 4x4 button and jump the 6 prong w/12volts to see if it will move.

I hope this helps someone out there.

Do you have the service manual pages that help you trouble shoot this? They are posted in the YotaTech link above for a 99' - page 18/19 of that post has the diagnostic pages you need for a 2001-2002. I have a similar issue on a 2001 that I'll be working on soon.

Sorry to revive this, but for those Google-ing this issue - or having flashing lights - this is important - the plastic transfer case actuator gear with the 3-contact metal wiper arm, IS REMOVABLE without splitting the transfer case, in 2001-2002 4runners - once removed, you can unbolt the actuator housing, 3 x 12mm bolts, and you can slide the housing off of the transfer case, exposing the notched metal rod that selects the 2wd/4wd in your case - this makes it easy to exercise the rod and place it in the correct position, mechanically speaking - 2wd, 4wd, and 4Lo/locked - then you can place/clock the actuator cover in the corresponding position - WHILE also placing the vehicle in 2wd/4Lo/4H via the lever and 4wd button in the correct position in the cab - prior to placing the key in the "on" position.

Once rod is in place - for me 4Lo was easiest, and I had to have the selectable lever inside the cab in 4Lo - the transmission was in neutral to achieve this manually for me - then place the cover on the contacts in the correct position, and boom, done.

This post (link) by "Mtns_Yo", posted below, is gold for those that want to see how to remove their actuator from 2001-2002 4runners - I somewhat disagree with his pictured timing marks though - however, do NOT be afraid to pull the gear mechanism out of the transfer case actuator - unlike 2000 and earlier years, our metal gear that locks in the transfer case sector rod, is attached to that plastic actuator gear, with the 3 metal contact wipers, via a spiral spring with a built in stopper - easy to put together even if it comes apart upon removal - just take your time, mine took time and penetrating fluid, it was a tight fit and didn't want to come out easily, had to wiggle one side at a time.

4wd not engaging in my 2001 4runner