Following for future reference. Good post.

Ok thanks. I ended up getting it back together but didn't try timing it. It has 278K on the transfer case so I'm going to replace it with a swap. Can get one for about $800. I got the truck from my dad and when I asked if he had problems with the 4wd before me he said yes..... Oh well I understand the problems and how it works a whole lot better now after diving into all of the threads.

What happens if you press the lower encoder button in? Does it do anything? I pressed it and get the transfer case lock light blinking and 4x4 light on steadily. Can that be reset?

I'm following this thread for reference. Looks like I might have to do something like this eventually.

Great thread- was able to solve the not engaging 4 HI/4LO on my 03-V8.

Took actuator cover off - expect a few pint or so of gear fluid to dump out.
Also the smallest gear and pin will want to slide out on you, so be ready to hold it in place if it moves (the one in upper right corner). I don't know if it can fully fall out, but mine moved like it wanted too.

I moved the worm gear with a small screw driver, less than a 1/4 turn/ freed it up.
Bolted it all back together.
Then proceeded with the procedure to put into 4 HI, roll back in neutral - put in drive, then reverse etc a few times. I felt it go into 4 HI but the light was still blinking, drove around the block carefully, then did the forward, roll back, neutral, reverse thing on a slight hill until the light stopped blinking.

Same for 4LO- it blinked and blinked. So did more of the into and out 4HI, and things seemed to get freed up and now goes into and out of 4HI/4Lo like it should.
I have 290K on this rig and there was no way in hell I was going to the dealer for a fix. Once again T4r delivers, many thanks.

Hello, I'm currently knee deep into the transfer case actuator on the rear of the transfer case. It's the one with two rods going into the TC. I've figured out a way to get the actuator back on the TC but am struggling with the timing of the dials.

Does anyone have any pics of the dials set for 2WD, High Range?

Initial problem was the vehicle would not go into 4 lo. Tried hitting the actuator with a rubber mallet, unbolting slightly and shaking etc. Ended up getting the Dorman replacement which looks like a good unit. In braking down the OEM unit off the car it seems the Lo-Hi DC motor was no longer working. Took it out tried overvolting it etc and couldn't get it to work. The hardest part was getting the actuator back on the TC with both rods sticking out. Had to rig up a small battery to engage the lo-hi gearing to pull itself back onto the TC. It's been a pain. Just need to get the timing right now so we can drive this thing again.


DL

2006 4Runner sport 4WD V6

Hi all.

Tell them that I also had this problem with the activation of the H4 and L4 because water entered through the vent.

I did a lot of searching around the sites, until I found a video on youtube where it shows the correct synchronization of the gears. I applied the same configuration and then in practice it was possible to activate the H4 without problems, as well as the central differential lock is activated and deactivated without problems, as well as the L4.

I leave the link, it is in Russian:
Toyota Land Cruiser 150. Ленд Крузер 150. Ремонт Раздаточной коробки АКТУАТОР .Советую посмотреть . - YouTube

I hope I can help you.

All the luck!.

New member, long time follower or page.

Dealing with the actuator issue on my 2004 V6. Rigjt now, it is 4hi (both the switch and the xfer case). The lights are: green solid, CDL yellow rapid flashing.

How do you "reset 4wd switch"? Did you mean the 4wd computer or the knob?
Anyone know how to reset the 4wd computer?

pull battery connections for a couple minutes should do it

Piggybacking on this thread. I recently replaced the TC actuator on my 07 v6. The original TC actuator seized and was stuck in 4LO.

I replaced it with a dorman actuator but now the 4LO light constantly flashes and I can only engage 4HI by turning the car off, switching it into 4HI, and turning the car back on. The 4wd switch doesn't work when the car is on and I suspect it has something to do with the 4LO light flashing on the dash. If I want to disengage 4HI, I have to turn the car off, switch into 2HI, and turn car back on and it will disengage 4HI. I cannot engage 4LO at all.

Additionally, when I engage 4HI, the CDL automatically engages and I can't disengage it at all.

I've tested the continuity between the actuator and the 4wd ecu and it's all good. I called dorman about this issue and they said I need to warranty the actuator. That is unfortunately what I will have to do but I wanted to see if anyone here has had a similar issue. I've tried searching the forums and despite the countless TC issues I've seen, nothing like this has come up.

Did you open the actuator up before installing? If you did, it might be a timing issue with the gears inside the actuator. I had the same issue with mine when I opened it up and didn't take note of what the gear positioning was.

I didn't open it. I made that mistake with the original actuator and didn't want to do that again. I have the v6 so I had to split the Transfer Case open to replace the actuator but that didn't require me to open the actuator.