2002 4wd won't engage

gmcmanus663

Member
Hello all. I'm having some issues with the 4wd on my 2002 ltd 4runner. Its the MM push button type with the green wheel and orange center lock indicator lights.

Before I explain I want to mention that I realize that I am not the first one to have this problem and I have looked through every thread I could find on this and can't seem to find my exact issue or solution. That is why I'm starting a new thread.

The basic rundown of my problem is that my truck will not shift into 4wd. I found that out the hard way on a beach. I did what I normally do and pushed the button on the t-case lever to engage normal 4wd. In the past it would either go straight into 4wd and illuminate the green wheels on the dash or they would all flash a few times and then I would get the clunk and it engaged.

This time I pressed the button, and it began flashing and hasn't stopped since.
Some important things I wanted to note was:

- I sat my phone recording under the truck and drove forward and back. The front driveshaft does spin but the truck is only in 2wd. I read that this is not good on another post.
- One fix that I saw very often was the front diff sensor (pt# 84222-35070). I don't know if this is because its an 02 but I could not find one on my truck. I used this thread (http://www.toyota-4runner.org/3rd-gen-t4rs/105547-bootowns-thread.html) for reference and took my own pics and its not the same. My truck doesn't have that position sensor.
- I also read about "tricking" the truck into 4wd using the vsv. Same story as the above switch. Do the 02s not use either of these systems for 4wd?

I know I've got an electric actuator on both the front diff and the t-case. I know that is a possibility for fault. What else should I look for/ test. Is there a 4wd relay? I know there is a small fuse in the cabin but what else?

Any help is greatly appreciated. I don't want to drive the truck much because of the front driveshaft not being free.

Thanks again for any help,
Grayson
 
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No the 01-02 does not use VSV components, electric.

High level questions, have you replaced diff fluids?

Do you have an FSM? That really is the best way to go about checking the various electronics variables.
 
Check the operation of the 4wd position switch on the transfer case actuator. If the front diff doesn't see the transfer case shift rod move it won't actuate the front diff (add). There should be 2 detection switches, can't remember which one is for 4H and 4L though, only 2 to check so it's pretty easy. I've replaced a few of those over the years for this exact issue.
 
No the 01-02 does not use VSV components, electric.

High level questions, have you replaced diff fluids?

Do you have an FSM? That really is the best way to go about checking the various electronics variables.

I haven't done the diff fluids since I got it. Unfortunately I'm away from home in college right now and don't really have a place to do it right now although I could take it to a shop :ohwell:
 
Check the operation of the 4wd position switch on the transfer case actuator. If the front diff doesn't see the transfer case shift rod move it won't actuate the front diff (add). There should be 2 detection switches, can't remember which one is for 4H and 4L though, only 2 to check so it's pretty easy. I've replaced a few of those over the years for this exact issue.

Thanks for the response, So what do those position switches on the t-case look like?
 
I had the 4wd blinky death lights in my 99 multi-mode. Changing TC and diff fluids cleared it right up. 9 months and a few dozen 4wd actuations later, no issues. Give that a shot before you worry yourself to death or start tossing parts at it.
 
I haven't done the diff fluids since I got it. Unfortunately I'm away from home in college right now and don't really have a place to do it right now although I could take it to a shop :ohwell:
Don't need a lift to change diff fluid. Vehicle can remain on the ground. Drain into a milk jug, and use cheap tubing to inject new fluid into diff. Piece of cake.
 
I had the 4wd blinky death lights in my 99 multi-mode. Changing TC and diff fluids cleared it right up. 9 months and a few dozen 4wd actuations later, no issues. Give that a shot before you worry yourself to death or start tossing parts at it.

Don't need a lift to change diff fluid. Vehicle can remain on the ground. Drain into a milk jug, and use cheap tubing to inject new fluid into diff. Piece of cake.

Yeah I'll just pony up this weekend and try and get it done in the parking lot. Hoping the campus safety doesn't come around cause I hear it's a bit frowned upon to wrench on campus :noidea: But that shouldn't be too big a deal.
 
Yeah I'll just pony up this weekend and try and get it done in the parking lot. Hoping the campus safety doesn't come around cause I hear it's a bit frowned upon to wrench on campus :noidea: But that shouldn't be too big a deal.
Tell em to go pound themselves. Lord knows you're paying enough in tuition.
 
Also I had a chance to get under the truck today and look around. I was able to find the detection switches on the transfer case. I'll attach some pictures here:

IMG_20160928_165155.jpgIMG_20160928_165217.jpg

Also this last picture shows something concerning. This is the actuator on the t-case. There's a crack as you can see along one of the bolts. Can't say how long its been that way. Maybe over-tightened by PO. Either way I'm definitely going to test the actuator itself because it looks like moisture could get through that and maybe mess some things up. It's a possibility so I'll check

IMG_20160928_165208.jpg
 

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