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Old 02-18-2021, 12:40 AM #16
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Quote:
Originally Posted by phattyduck View Post
Toyota normally calls them VSV = vacuum switching valve... but same thing.

On the '96-'00 non-Limited, the only actuator is the vacuum ADD actuator on the front diff. A switch on the transfer case activates the relay in the passenger footwell, which powers the VSV's to swap vacuum direction on the ADD actuator. When the ADD actuator moves, it hits a switch that turns on the dash light.

Since you hear the ADD relay working, the transfer case portion of the system is working. Check the ADD vacuum lines. Check the VSVs themselves. If 4WD *feels* engaged but the light is off, it could just be the indicator switch on the front diff.

Also, things could just be sticky due to non-use. The system should be actuated at least 1 a month. Toyota says 5-10 miles every month. Just pick a straight section of road and engage 4WD every so often. I just do a couple of side streets every month (put it in 4WD at a stop light/sign - then disengage next time I have to turn).

-Charlie
Thanks again Charlie
I am indeed guilty of not exercising the system as i should... However i have done it in the past but not nearly as what is recommended.I'll start tomorrow looking things over. Oh.. 4WD does not feel engaged due to fishtailing all over the place.. when it was working that day all i had to do was tap on the throttle and all 4 Duratracs pulled me where i wanted to go.. when it stopped- so did i!
Again thank you.
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Last edited by giguchan; 02-18-2021 at 12:45 AM.
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Old 03-01-2021, 12:52 AM #17
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**An Update Not a big one but one just the same.

I crawled under the truck and check for everything
that i was advised to from Members on this board.I
could not find any wiring issues nor any vacuum hoses
that messed up either. I had to bring the truck in for it's
Oil change and while there i asked them to have a look.

The dealer struck out also.I received a lot of excuses from the Service advisor is all i got. The only excuse i am buying is that while i was there on a Saturday GET EM IN GET EM OUT! they could not spare one tech to actually DO any trouble shooting.. What is needed is a Tech who works on these old trucks..
Luckily i think i found one. More next time.
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Old 03-12-2021, 03:43 PM #18
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Another quick update

Hey all,
It has been determined that the Front diff actuator is indeed bad.
Has anyone had any success in replacing this(with limited tools and know how) or is this better left to the Dealer? I was quoted out the door $800 minus the diag service Fee.The Part itself isn't too bad@$375.
Thanks.
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Old 03-12-2021, 04:13 PM #19
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Quote:
Originally Posted by giguchan View Post
Hey all,
It has been determined that the Front diff actuator is indeed bad.
Has anyone had any success in replacing this(with limited tools and know how) or is this better left to the Dealer? I was quoted out the door $800 minus the diag service Fee.The Part itself isn't too bad@$375.
Thanks.
The worst part will be dropping the front diff. Here's a video of the front diff removal: https://www.youtube.com/watch?v=w_gPiDvh9v4
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Old 03-12-2021, 04:48 PM #20
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Quote:
Originally Posted by Bad Luck View Post
The worst part will be dropping the front diff. Here's a video of the front diff removal: https://www.youtube.com/watch?v=w_gPiDvh9v4
I think you can replace the actuator with the diff in the truck...

-Charlie
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Old 03-12-2021, 06:32 PM #21
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Quote:
Originally Posted by phattyduck View Post
I think you can replace the actuator with the diff in the truck...

-Charlie
I wasn't sure if there was enough room to pull the actuator out all the way for the shift fork (probably the wrong word but the part that moves the engagement mechanism in the ADD). If there is then that will save the OP a ton of work!
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Old 03-13-2021, 09:43 PM #22
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The Part has been ordered. I will indeed look into if it can be removed/installed without dropping the Front Diff.

That would explain the 4 hrs Labor.

Thanks Guys.
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Old 03-19-2021, 11:26 PM #23
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+1 on the vacuum lines.
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Old 03-20-2021, 01:29 AM #24
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I wish it was a few Vac Lines.... I aint got that kinda luck...
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Old 05-22-2021, 08:08 PM #25
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An update on this issue..

I dropped off my truck the other day only to get it back today and after $1k late the problem still isn't fixed.

The dealer diagnosed the issue as a Bad actuator and apparently not available through Toyo anymore so they had to go aftermarket. They replaced the the front differential actuator and it still does not work as it's supposed to.

The Good folks on this Board suggested that it might be the Vacuum portion of the system. They're telling me that isn't right.

More when i return on Monday.
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Old 05-23-2021, 10:49 AM #26
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Are you sure you are hearing the relay activate?

Get a volt meter and measure if you have 12v to the VSV's. One should get 12v in 2wd and the other in 4wd. If you have 12v to each one when the shift lever is in the appropriate position pull the vacuum line and see if you actually have vacuum. If one does not get 12v then you have a 4wd switch bad, relay bad, or wiring issue. If each has 12v in the appropriate position and you don't have vacuum, then bad VSV. If you do have vacuum then you have a vacuum leak or the actuator is working and the indicator switch in the diff is bad.

If your 2wd VSV is working and your 4wd VSV is not you can put the truck in 4wd, switch the vacuum lines between the 2 VSV, 4wd should then activate and the indicator on the dash will light. This will at least verify that 4wd is mechanically sound.
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Old 05-23-2021, 01:42 PM #27
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Hey there,
I do hear the relay switching in the kick panel on the passenger side. when i go to switch in 4WD and back out again. But No Illumination on the panel.

Thank you for the suggestion. If i can get the time i'll try your suggestion. Can you tell me if the Actuator is visible from under the Truck? I would like to see exactly what they are doing under there.

It's going back tomorrow.

The advisor also said something about the OEM parts from Toyota are long not available. so they had to go aftermarket.
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Old 05-24-2021, 08:27 AM #28
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I had the exact same symptoms you have. It ended up being a bad VSV. Use the procedure mentioned above to test the VSV's, that's how I found out mine was bad.

I have a parts truck so I swapped the bad VSV and my 4WD has worked perfect ever since.
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Old 05-24-2021, 10:43 AM #29
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Quote:
Originally Posted by thegipper View Post
I had the exact same symptoms you have. It ended up being a bad VSV. Use the procedure mentioned above to test the VSV's, that's how I found out mine was bad.

I have a parts truck so I swapped the bad VSV and my 4WD has worked perfect ever since.
This ended up being the problem with my truck as well. I initially thought it was my ADD actuator, but I had no vacuum going through either of the lines. The truck mostly sitting for 3 years seized both of my VSVs.

OP you should really just pull both long hoses for the VSVs and feel with your finger if one gets vacuum in 2WD and one gets vacuum when you click it to 4WD.

I can offer further testing advice for the ADD actuator if at least of them does get vacuum while you check the VSVs.
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Old 05-25-2021, 06:38 PM #30
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Quote:
Originally Posted by thegipper View Post
I had the exact same symptoms you have. It ended up being a bad VSV. Use the procedure mentioned above to test the VSV's, that's how I found out mine was bad.

I have a parts truck so I swapped the bad VSV and my 4WD has worked perfect ever since.
I heard from the dealer today.. The NEW Tech who did the latest Troubleshooting Came back with the same diagnosis.
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