[dave4242]

I typically switch between 4Hi and 4Lo every month or 2. This morning, I decided to do it again. Put truck in neural, switched to 4Lo. It blinked but did not stay with steady light. I then switched back to 4Hi. But truck is definitely still in 4Lo. I tried rocking it back and forth....going from reverse to drive. Put it in neutral and tried shifting back. Still in 4Lo. I go under it and rapped actuator. Still nothing. Any other tricks? I never even heard the typical clunk that I would get when shifting into Lo. And definitely no clunk trying to go back to Hi. I read a few posts here and don't see anything besides what I've done. thanks

[ArthurKotb]

If the light was blinking doesn't that mean it didn't shift the transfer to Lo?
Locking center differential isn't engaged, is it?
Neutral position and turn motor off/on ?

[dave4242]

Center diff not locked. 4Lo flashed. When I turn to 4Hi, lights are off. But truck definitely is in 4Lo. Transmission making whining noise like it’s in Lo.

[dave4242]

4Lo flashing tho my switch is at 4Hi. truck is definitely in Lo. Diff lock is not lit. I removed 4WD fuse and put back in, but that did nothing

[dave4242]

Just an update in case it helps someone else. Got underneath with a hammer and kept smacking the actuator and trying the switch. After about 10 attempts, I get a weird grinding noise and 4Lo stayed lit. Then I switched back to 4Hi and she’s good. Now I’m scared to death to ever touch it again. I’ve never actually used 4Lo in an emergency situation so I’m inclined to never turn it again as the fix would have been astronomical.

[ArthurKotb]

Since I have an '04 V8 4X4 I'm curious. You say you exercise it about every other month. Since I got my '04 in fall 2003 I think I have put it in Lo maybe 2 times. One of those was last year. It didn't have any problem either time. I did have a transfer case (small) oil leak a couple years ago and had it fixed. I don't know if they checked it out or anything.

I have almost 140K miles right now, never have taken it off road or even in the snow in all that time. For the first 10 years of ownership I drove it 50 miles round trip to work once every other week. Now I pull a 23', 6500 lb. Airstream and 17', 2200 lb Ranger bass boat with it. My T4R has been well cared for but not garage kept.

How does that compare to your driving?

[dave4242]

Ours also an 04. It’s a Limited V8 with 135,000 miles. Used to be a daily driver but for the past 4-5 years, it’s at a weekend place so limited driving. I keep it up but honestly it’s mostly maintenance stuff. It is garaged but the northern winters have taken a toll underneath as far as general corrosion. Frame is decent. Never have I tried to use 4Lo to get me out of a situation. It handles so well without it. I don’t tow anything except the occasional UHaul. I don’t think I’ll chance messing with that switch again because the thought of spending thousands had me ready to sell it. Do you exercise the actuator each month? If not, I wouldn’t take that risk trying it at this point.

[ArthurKotb]

I've put it in 4 Lo twice since I've owned it; never went more than 100 yards in Lo. I used the locking center differential in the snow once or twice. There was a small leak in the transfer case that I had a trusted repair shop fix for me and it wasn't cheap. Like yours, mine has been great, maintenance and minor repair. I had an O2 sensor replaced maybe 8-9 years ago. That and the transfer case leak have been the only repairs I haven't done myself. I replaced the rubber trim around the rear window last year because I kept smelling exhaust. I have replaced the spark plugs and air/cabin filters. I have also replaced the brake pads, front calipers and all rotors. Almost no rust in the frame; very light. I had the spare tire cable mechanism freeze up. Tire came down, wouldn't go back up. I spent an afternoon shooting WD-40 and some spray lithium into the mechanism, cranking back and forth with a socket after I took the cover off and finally got it free. Now it's an annual maintenance item

My oldest son lives in Plymouth, MN, just north of Minneapolis. He drives in all the harsh winters with his 2006 SE V8 4X4. Frame has some rust but it's still not too bad. He's facing the manifold replacement for the 3rd year now. It makes noise when he starts it up but after that the heat seals it and it quiets down. I think he's around 170K miles.

[gaber6]

Originally Posted by dave4242

Just an update in case it helps someone else. Got underneath with a hammer and kept smacking the actuator and trying the switch. After about 10 attempts, I get a weird grinding noise and 4Lo stayed lit. Then I switched back to 4Hi and she’s good. Now I’m scared to death to ever touch it again. I’ve never actually used 4Lo in an emergency situation so I’m inclined to never turn it again as the fix would have been astronomical.

I'd do the opposite. I'd flip it back and forth 20 times and roll around to bust off any corrosion that's making it stick. I don't know anything about transfer cases but I did stay at a holiday inn Express last night

[dave4242]

Originally Posted by gaber6

I'd do the opposite. I'd flip it back and forth 20 times and roll around to bust off any corrosion that's making it stick. I don't know anything about transfer cases but I did stay at a holiday inn Express last night

Yeah. My first thought was it would probably make sense to keep exercising it. But it was stuck for hours. Had to drive it home about 15 miles in 4Lo. I’m sure that wasn’t great for it. If it were to stick again, I’d probably get rid of the truck as $2000-3000 is way too steep a repair

[dave4242]

Originally Posted by ArthurKotb

I've put it in 4 Lo twice since I've owned it; never went more than 100 yards in Lo. I used the locking center differential in the snow once or twice. There was a small leak in the transfer case that I had a trusted repair shop fix for me and it wasn't cheap. Like yours, mine has been great, maintenance and minor repair. I had an O2 sensor replaced maybe 8-9 years ago. That and the transfer case leak have been the only repairs I haven't done myself. I replaced the rubber trim around the rear window last year because I kept smelling exhaust. I have replaced the spark plugs and air/cabin filters. I have also replaced the brake pads, front calipers and all rotors. Almost no rust in the frame; very light. I had the spare tire cable mechanism freeze up. Tire came down, wouldn't go back up. I spent an afternoon shooting WD-40 and some spray lithium into the mechanism, cranking back and forth with a socket after I took the cover off and finally got it free. Now it's an annual maintenance item

My oldest son lives in Plymouth, MN, just north of Minneapolis. He drives in all the harsh winters with his 2006 SE V8 4X4. Frame has some rust but it's still not too bad. He's facing the manifold replacement for the 3rd year now. It makes noise when he starts it up but after that the heat seals it and it quiets down. I think he's around 170K miles.

I also replaced a couple oxygen sensors over time. I do the brakes myself. I have a coworker who is a shade tree mechanic. He replaced my steering rack and pump as well as ac compressor and XREAS with regular shocks. I’m getting ticking when I first start truck but no CEL. In MA, once a vehicle is 15 years old, there’s no emissions testing.

[ArthurKotb]

Originally Posted by dave4242

I also replaced a couple oxygen sensors over time. I do the brakes myself. I have a coworker who is a shade tree mechanic. He replaced my steering rack and pump as well as ac compressor and XREAS with regular shocks. I’m getting ticking when I first start truck but no CEL. In MA, once a vehicle is 15 years old, there’s no emissions testing.

That seems to be a lot of work. I guess the ice and snow take their toll up there. I was fortunate enough to have a 'beater' car to drive the 46 mile round trip through that kind of weather. The '91 Camry didn't seem to mind, except for the bottoms of the doors. That's where it got a lot of rust.

My A/C is still working fine and I really like the X-REAS when I'm towing the Airstream. It really helps with the handling.

I got the JBL radio with 330 watt amp and 10 speaker. I wanted Bluetooth and external jack for my Sirius head unit, but it wasn't available at that time. About 3 years ago I found a device on Crutchfield. It fits in the glove box with wires going over to the radio. It works great. There's a USB connection for plugging in a charger, external jack and Bluetooth with microphone for the phone. It's been really great. I also have the inverter option with a plug at the bottom of the center console. That's been very handy also.

I intend to keep mine for as long as possible. It's been a great SUV