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Old 08-29-2013, 01:58 PM #16
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Took the truck to my repair shop (not a dealer) this morning. The owner thinks putting a new shaft with new joints and boots will fix it after hearing the noise. I sure hope so! I will let you all know if that does the trick.
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Old 08-29-2013, 02:10 PM #17
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Holy crap this thread is hard to follow. It was sounding to me like his noise was happening as soon as he shifted to 4-HI (while sitting still) which would be the t-case actuator not engaging fully. That would be a major problem.

But now the mechanic says it's the shafts...which could only be the case if the noise is NOT happening while sitting still.

Wow.. waiting to hear the outcome.
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Old 08-30-2013, 10:43 AM #18
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Quote:
Originally Posted by 8borerifle View Post
Took the truck to my repair shop (not a dealer) this morning. The owner thinks putting a new shaft with new joints and boots will fix it after hearing the noise. I sure hope so! I will let you all know if that does the trick.
He is wrong. Find a new shop. The axles and not your problem, they would make noise non-stop if that were the case since they spin all the time. You probably have a problem with the engagement mechanism in the front axle. This is unrelated to the "shafts" although if the boot is torn that obviously needs attention.
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Old 08-30-2013, 03:50 PM #19
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Lehiguy I happen to agree with you. The noise seemed to change a lot when I put I put it in 4wd. When it first happened the truck was in 4wd on a dirt road moving and it started to sound like a brake pad warn riding on a warped rotor. I later put the truck in 4wd while it was still and the minute I moved it it sounded like my old Mustang Bullitt 5 speed with syncronizers going bad grinding between gears. Sometimes the noise is louder than other times. I hope it is not the front actuator. Trade in value I would guess on the truck is only about 6,000 dollars so sticking 2500.00 into a repair is a lot of money. I might be better off trading it of and hoping the dealer would only decrease the trade-in value by what the dealers cost for repair would be. What to do what to do! I guess I don't have enough info yet! Thanks for your input and the other guys too!
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Old 08-30-2013, 06:29 PM #20
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Originally Posted by 8borerifle View Post
Lehiguy I happen to agree with you. The noise seemed to change a lot when I put I put it in 4wd. When it first happened the truck was in 4wd on a dirt road moving and it started to sound like a brake pad warn riding on a warped rotor. I later put the truck in 4wd while it was still and the minute I moved it it sounded like my old Mustang Bullitt 5 speed with syncronizers going bad grinding between gears. Sometimes the noise is louder than other times. I hope it is not the front actuator. Trade in value I would guess on the truck is only about 6,000 dollars so sticking 2500.00 into a repair is a lot of money. I might be better off trading it of and hoping the dealer would only decrease the trade-in value by what the dealers cost for repair would be. What to do what to do! I guess I don't have enough info yet! Thanks for your input and the other guys too!
The repair shouldn't be $2500 for replacement of the ADD actuator; you might be confusing it with the transfercase actuator.

The only issue is from your first post it sounds as though the transfer case actuator had been replaced before, not the ADD. The issue at the moment is that you need to find out what else beside the ADD has gone bad. It sounds like the synchronizer ring is not meshing properly with sleeve inside of the front differential housing, so before you have the ADD replaced you need to see what the damage inside is and decide if it needs a new 3rd member.
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Old 08-30-2013, 07:07 PM #21
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BlackWorksInc thanks for your help! I was hoping you would post as you really know what you are doing. I am sure the transfer actuator was never replaced as I bought the 4Runner new and I have only had brake service done (sticking caliper and rotors). It is very hard to describe the sound as it seems to change. At one time it sounded like missing a gear and the grinding sound from that. Now when I put it in 4wd it is a pulsing sound that increases in speed as the vehicle speeds up. I hope it is not the 3rd member that is bad, the only Toyota dealership around here is a ripoff artist and would not trust them to give me an honest report as to what is wrong. What would it cost in your estimate to change the front actuator? But then there might be damage inside the third member. It really sounds like a worn brake pad rubbing on a warped rotor, but it only makes the noise in 4wd. The brakes are fine on the car and were replaced about 3000 miles ago. At first with the sound like missing a gear and grinding, I thought the sleeve or shaft were bad, but then it quite making that sound.
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Old 08-30-2013, 08:05 PM #22
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I'm sorry I misread the post below your original post as yours and mistakenly assumed it was in regards to your vehicle history.

41400-35032 is the part number for the ADD, it is roughly $300, the entire front 3rd member is about $1500 with a new ADD included.

Labor is about 2.0hrs for the ADD and about 2.5hrs when replacing the entire 3rd member.
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Old 08-30-2013, 08:07 PM #23
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Can you use your phone or camera to make a video of the noise and put it on youtube?
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Old 08-30-2013, 09:41 PM #24
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I should have the truck back next week so I could use my phone to record the noise then. I am hoping the new axle assembly will fix it but that doesn't seem likely. I overestimated the cost of repair, it might not be too bad even if the third member needs replaced. Even at 100/hour the total cost for the 3rd member might not be over 1800.00. Thanks BlackWorksInc for the repair estimate. I was thinking I would have to get a junk yard third member and have it installed. Don't see how you could do that in 2.5 hours, but being on a lift sure would make a difference! I have changed a ton of engines when I was younger, even putting an 87 Buick Grand National drivetrain in a Monte CarloSS. That opened a few eyes at the drag strip when I was running 12.60's with street tires and closed exhaust. I kept the hood closed! I am too old to do that stuff now, bad knees and hip and bifocals. Dang!
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Old 08-30-2013, 10:22 PM #25
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I should have the truck back next week so I could use my phone to record the noise then. I am hoping the new axle assembly will fix it but that doesn't seem likely. I overestimated the cost of repair, it might not be too bad even if the third member needs replaced. Even at 100/hour the total cost for the 3rd member might not be over 1800.00. Thanks BlackWorksInc for the repair estimate. I was thinking I would have to get a junk yard third member and have it installed. Don't see how you could do that in 2.5 hours, but being on a lift sure would make a difference! I have changed a ton of engines when I was younger, even putting an 87 Buick Grand National drivetrain in a Monte CarloSS. That opened a few eyes at the drag strip when I was running 12.60's with street tires and closed exhaust. I kept the hood closed! I am too old to do that stuff now, bad knees and hip and bifocals. Dang!
I replaced the front 3rd member in my 4Runner a year ago, was pretty straight forward. Once you get the two brackets off and pop the axle shafts out its just a heavy SOB to lug in and out.
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Old 09-01-2013, 06:59 PM #26
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Found the problem and will pick the 4Runner up Tuesday! Turns out the shield over the cat. convertor had rusted off and was laying across the driveshaft going to the front axle. Every time 4wd was activated the noise started and got faster as the speed increased. Thanks for all your help. The shop put it on a rack and activated 4wd and the wheels were turning fine but the noise couldn't be found until they found the shield! Thanks a lot for all of your help, glad it wasn't the actuator or third member! As soon as the shield was removed the noise stopped. The drivers side axle assembly will be installed Tuesday to fix the torn boot.
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Old 09-01-2013, 08:34 PM #27
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Thanks for posting the outcome.
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Old 09-03-2013, 06:13 PM #28
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Got the 4Runner back today from the repair shop. Drivers side axle assembly replaced, total cost $204.41. Owner showed me the Aluminum heat shield that fell on the shaft that made a lot of noise when 4wd activated. Looks like the metal ate away around the three bolts that held it on. Glad that was all it was!
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Old 10-17-2021, 04:03 PM #29
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Horrible noise after tight turn in 4H

Apologies for jumping on this thread, but I'm new to this forum and it wouldn't let me post a new thread. I fear I've made a terrible mistake and would love to hear ideas/advise.

I have a 2003 4Runner SR5 V6. I've purchased it used a few months ago. It's got 130,000 miles.

I was just driving for one of the first times with it in 4H. I made a tight turn in a slushy dirt parking area and it wade a horrible grinding crunching sound. While in 4H, I have no drive or reverse and it continues to make a noise. The sound goes away when in park. And everything is fine in 2H.

What have I done?!?!

Thanks so much for your help!
-J
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Old 10-17-2021, 06:50 PM #30
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Apologies for jumping on this thread, but I'm new to this forum and it wouldn't let me post a new thread. I fear I've made a terrible mistake and would love to hear ideas/advise.

I have a 2003 4Runner SR5 V6. I've purchased it used a few months ago. It's got 130,000 miles.

I was just driving for one of the first times with it in 4H. I made a tight turn in a slushy dirt parking area and it wade a horrible grinding crunching sound. While in 4H, I have no drive or reverse and it continues to make a noise. The sound goes away when in park. And everything is fine in 2H.

What have I done?!?!

Thanks so much for your help!
-J
Take a look under the truck and rule out anything obvious like a broken front drivevshaft/yoke/etc.
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