2002 4wd won't engage

[gmcmanus663]

Slap some 12v on the appropriate leads and see if the solenoids move correctly.

Okay I've got access to TIS so that should be a breeze. Quick question/opinion. I was thinking about this yesterday and when I test the solenoid movement I should know. I mentioned earlier that my driveshaft is locked and moves when the truck is in drive. So to me it seems like the transfer case is actuating properly because with the front jacked up the wheels are free, so clearly the front diff is not. So then the position switches on the transfer case that I took pictures would make sense to be the culprit here. I'll know for sure this weekend just figured I'd see what you thought.

 

[gmcmanus663]

Okay so the Florida weather has been against me but I've got an update.

Today I was able to change out the diff and transfer-case fluids. I drove the truck around and did the normal back and forth and no dice. Still the same problem. I actually ended up buying a replacement 4wd sensor that goes on the transfer case last week because I got it cheap and decided I'd try that out. Again no change so I can eliminate those two for now.

I didn't have a chance to test the actuator but that is going to be my next move. I'll update with any questions or new info when I get a chance to work on it. Word on the street is a hurricane is on the way so we'll see eep:

 

[Desertwind16v]

Okay so the Florida weather has been against me but I've got an update.

Today I was able to change out the diff and transfer-case fluids. I drove the truck around and did the normal back and forth and no dice. Still the same problem. I actually ended up buying a replacement 4wd sensor that goes on the transfer case last week because I got it cheap and decided I'd try that out. Again no change so I can eliminate those two for now.

I didn't have a chance to test the actuator but that is going to be my next move. I'll update with any questions or new info when I get a chance to work on it. Word on the street is a hurricane is on the way so we'll see eep:

Are you sure you replaced the correct sensor? One will be for 4H and the other for 4L. A simple check I use is to take a jumper wire, unplug the connector on the detection switch and plug the jumper into the connector. It will simulate the detection switch. You're front drive shaft turns so you know the t-case actuator is working fine. I really think it's that switch for 4H on the t-case, use TIS to figure out which one is which, push the 4WD button, then go under the truck and plug in your jumper, see what happens.

 

[gmcmanus663]

Are you sure you replaced the correct sensor? One will be for 4H and the other for 4L. A simple check I use is to take a jumper wire, unplug the connector on the detection switch and plug the jumper into the connector. It will simulate the detection switch. You're front drive shaft turns so you know the t-case actuator is working fine. I really think it's that switch for 4H on the t-case, use TIS to figure out which one is which, push the 4WD button, then go under the truck and plug in your jumper, see what happens.

Okay great I'll do that. Hopefully I will be able to do it Sunday. Hurricane Matthew is supposed to hit where I am late Thursday into Friday and I'm headed to the west coast of Fl. Like I said the weather is always against me :redbrick:

 

[JoshD21]

Did you ever figure out the problem? My truck (02') is stuck in 4wd and I'm researching how to troubleshoot it.

 

[gmcmanus663]

Did you ever figure out the problem? My truck (02') is stuck in 4wd and I'm researching how to troubleshoot it.

Hey I'm sorry for the lack of updates. I haven't been able to do much with the truck lately. School and all has been in high gear. I'm going to try and use the jumpers mentioned earlier sometime this week to try and figure something out. Hopefully I can eliminate some possible options and if I'm lucky find the culprit.

I'll make sure to post as soon as I know anything.

 

[Pedrojr80]

Did you ever figure out the problem? My truck (02') is stuck in 4wd and I'm researching how to troubleshoot it.

Try to tap the rear actuator and see if u can hear the actuator moving and if u dont u might going to need another actuator and if is like my case i had to get me the whole transfer case since u got to dissemble the whole tc to replace the actuator

 

[gmcmanus663]

Try to tap the rear actuator and see if u can hear the actuator moving and if u dont u might going to need another actuator and if is like my case i had to get me the whole transfer case since u got to dissemble the whole tc to replace the actuator

I really hope that isn't the case. If it is I can't do anything about it until my school winter break. All I have down here with me is a toolbox of essentials and a parking lot that they don't like us working in.

Hopefully I'll know either way sometime this week

 

[Vitamin_E]

I'm interested to see what you find. I'm having a similar issue with my 98. Have you tried driving around with 4wd on for a while? I'm not sure how the 02's work, but for some reason when I shift into 4wd it won't engage right away, but if I drive around for a mile or 2 it'll finally engage and the dash light comes on. It's really aggravating. But yeah like I said, I don't really know about the 02's

 

[Ay Ay Ron]

best of luck, trying to fix my 90 4wd as we speak

 

[jgue467]

Mine was sticky, blinky 5 years ago when i got it. Changed fluids twice. Not sure that made much difference.

Then purely by accident I once engaged 4wd just before a Right turn at my deer lease. Click it engaged during the right turn. Then again by accident I disengaged just before a Left turn and click disengaged.

I know its hokey but it worked for me most everytime. Once or twice it didn't want to disengage but everytime i didn't make that left turn it stuck. Those were 'scary' cuz i could feel the binding - not a good feeling, then I would try turning left while still binding and click it disengaged.

Now after a couple years of repeated use, it now engages/disengages without the need for the hokey turns. Just thought I'd pass along what seems to have worked out for me. Luck. :cowboy:

 

[phillyd162]

Mine was sticky, blinky 5 years ago when i got it. Changed fluids twice. Not sure that made much difference.

Then purely by accident I once engaged 4wd just before a Right turn at my deer lease. Click it engaged during the right turn. Then again by accident I disengaged just before a Left turn and click disengaged.

I know its hokey but it worked for me most everytime. Once or twice it didn't want to disengage but everytime i didn't make that left turn it stuck. Those were 'scary' cuz i could feel the binding - not a good feeling, then I would try turning left while still binding and click it disengaged.

Now after a couple years of repeated use, it now engages/disengages without the need for the hokey turns. Just thought I'd pass along what seems to have worked out for me. Luck. :cowboy:

Good info...mine is months in after being stuck "sorta on" blinking and grinding on certain turns, and now after multiple fluid changes and both the front and rear actuator sensors changed, keeps doing the same but with less grinding. Seems like one of those things...hit it on the right day and knock it back out, but you never know.

 

[gmcmanus663]

Mine was sticky, blinky 5 years ago when i got it. Changed fluids twice. Not sure that made much difference.

Then purely by accident I once engaged 4wd just before a Right turn at my deer lease. Click it engaged during the right turn. Then again by accident I disengaged just before a Left turn and click disengaged.

I know its hokey but it worked for me most everytime. Once or twice it didn't want to disengage but everytime i didn't make that left turn it stuck. Those were 'scary' cuz i could feel the binding - not a good feeling, then I would try turning left while still binding and click it disengaged.

Now after a couple years of repeated use, it now engages/disengages without the need for the hokey turns. Just thought I'd pass along what seems to have worked out for me. Luck. :cowboy:

I'll have to give that a try, thanks!

 

[4runnerWiniarski23]

So I wanted to let you know whats worked for me.

About a month ago I blew out my rear diff/driveshaft. I got a new rear diff from east coast gear and a local driveshaft.

Fast forward got the truck back running in 2wd. I tried out the 4wd to make sure everything was working properly.


When i first tried the 4wd I could not get it to engaged no matter what I would do. Similiar to your situation. What i did was put the transfer case into neutral with the 4wd button not pressed (2wd), make sure all the lights are off on the dash. This puts the transfer case and the electronics on the same page. What i found was that my transfer case once in neutral the 4wd lights were engaged but my button wasnt. I pressed the button and put transfer case back into 4hi. The truck drove normal, i disengaged the 4wd and it clunked out. After I got everything on the same page, I still have problems but I know it was engaging.

I have noticed since I swapped my driveshaft and diff that I can no longer swap to 4hi on the fly. I have tried rolling around 15 mph and i get a lot of binding and grinding. Sometimes i even get some tire chirp. I immediately stop, switch between neutral, reverse, and drive a few times, and drive a few hundred feet and i can almost everytime get it to swap into 4hi. The truck drives fine once it is finally engaged but I noticed if i do not let it engaged i get alot of what i think is binding. The truck almost feels like its pushing the front wheels. I thought I might have a problem with my transfer case but it does engage when I stop and switch between neutral and drive a few times.

I think i will swap the fluids and see if that helps with engaging on the fly. I used to be able to swap going 40mph down the road, I did it on multiple occasions without any clunk and chirp at all, I did not even hear any grinding/binding. I think theres a chance I am low on fluid in the transfer case thats why the truck has a hard time engaging at speed.

Sorry for the long post and I hope it makes some sense. In my case everything was out of wack.

best of luck and hopefully you get it working soon, winter is coming!

 

[Plastics guy]

Is the orange light in the center of the 4wd indicator light on? I have an 02 as well and have gone through this problem before. I'm pretty familiar with the system.

If the orange light is not lit the problem is in the front actuator. Let me know. We'll go from there

 

[gmcmanus663]

Is the orange light in the center of the 4wd indicator light on? I have an 02 as well and have gone through this problem before. I'm pretty familiar with the system.

If the orange light is not lit the problem is in the front actuator. Let me know. We'll go from there

Yes the orange light is flashing along with the 4 green tires on the dash.

 

[redbirds5]

Yes the orange light is flashing along with the 4 green tires on the dash.

Keep trying it will work.


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[gmcmanus663]

Keep trying it will work.


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What do you mean keep trying? Trying what specifically?

 

[redbirds5]

What do you mean keep trying? Trying what specifically?

Every time you get in it engage it let it try .. then disengage it drive around then try again when you get home .. mine was that way hopefully it's not seized up


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[redbirds5]

What do you mean keep trying? Trying what specifically?

Every time you get in it engage it let it try .. then disengage it drive around then try again when you get home .. mine was that way hopefully it's not seized up


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