02 4runner going in & out of 4wd by itself!!

[yotababs86]

I have a 2002 4runner SR5 Sport Edition. I recently purchased this vehicle and so far it has been nothing but a headache. The transfer case was leaking so I removed it and replaced all of the seals on the exterior case and the companion flanges for the shafts. I put it back on the vehicle on everything works great. I recently was told by my wife that when she was driving it, it felt like the acceleration just stops at certain times. She said that this happened one time before I put the new seals in. I drove the truck and she is correct, you will be driving along and it will just feel like you brake check yourself. After driving the truck some more and trying to pin point what is going on. I have come to the conclusion that the truck is putting itself into 4wd with no command of the driver. When it does this the indicator does not come on. After you feel it go into 4wd by itself, if you slow down, you hear a clunk like it pops out of 4wd and the steering and acceleration all goes back to normal. I have a pretty good mechanical background, just not in 4wd. Motorcycles are more my cup of tea. I need some help on where to start looking for this issue. I do not want my wife to be driving down the road and have the transfer case lock up solid. Please Help!!!! I posted another thread about the transfer case leaking and no one responded...

 

[4-Ripcord]

What do you do that gets the truck to do this? Does it do this when you corner then accelerate? Accelerate from a stop light? Accelerate particularly fast? Etc..

Check the wiring on the 4wd button on the transfer case shifter. It may just be shorting and thinking you pressed that button. That would be my first guess.


But FYI, even if it got into 4wd and stayed there, its ok to drive on the streets. 01-02 have a feature called multimode. Its basically AWD until you activate the center diff lock to make it true 4x4. So its safe to drive on the streets even if the T-case engages on its own. Not saying its OK thats its doing this, just letting you know that its still ok to drive if you still need to drive it.

This will tell you more about that.. http://www.toyota-4runner.org/3rd-g...rs-3rd-gens-transfer-case-awd-multi-mode.html

 

[yotababs86]

I just noticed it when driving around normally. We live in an area where the speed limit is 30 mph. I noticed that it happened about 5 times within about 10 miles of driving 30 mph. I do not believe that it has anything to do with turning or accelerating. When it was happening for me, I was traveling at 30 mph constant with my foot lightly on the pedal. When it happens, you can hear it go into 4wd, the steering gets stiff and if you let your foot off the gas then it slows down pretty fast. Sometimes when it happens, if you slow down quickly then it will pop back out. I do plan on checking the connection of the button since i had that off to repair the tcase seals. The only reason why i dont think that it is the button is because the dash light doesnt come on at all. Thanks for that link, I will read through that. I also was thinking about putting it on jacks and trying to see whats going on under there, I know that it kind of sketchy though.

Nice truck by the way....

 

[4-Ripcord]

Thanks.

So this didn't start until after you did the work on the T-case right? I would just check all the plugs. Maybe disconnect the battery if you haven't already. Its electronically activated, so its most likely something to do with wiring.

 

[20034RunnerV84x2]

Its either the wiring or there is dirt in the button and it messing it up.

Also, make sure there are no codes by plugging in a scanner and seeing if there are but not setting the CEL.

Good luck.

 

[yotababs86]

ok so I just went for a little joy ride. when i started out, it was in 4wd already. The indicator was not on. I was driving at about 30 mph and I hit the button, nothing changed because it was already in 4wd, except the light came on. I hit the button again to take it out of 4wd and the light went off, but it stayed in 4wd. I came to a stop and I put the truck in neutral and then put the tcase lever in neutral which should get the "A/T P" light to come on but the 4wd indicator came on. WTF?! I am going to get back in there this weekend and verify everything. I am pretty sure that I did not switch anything because i color coordinated things before removing them but it doesnt hurt to double check. Also, does anyone know how the No. 1 and No. 2 4WD switches work on the actuator? What are their purposes? The No. 2 4WD switch has rtv or something in it from the previous owner. I will be sure to disconnect and reconnect the battery and check for codes also

Ripcord - my wife said that it happened one time before i fixed the tcase leak. she said that she was going about 70 mph and it scared the **** out of her.

 

[yotababs86]

ok so it didnt do anything for about two days. It is now back and it is doing it pretty violently. It has been happening around 40 mph. I done all of the following recommendations listed above. I disconnected the battery, I checked for codes, I checked resistance on the switch and the actuator per the FSM. I dont know what is going on. Does anyone have any other ideas?