2002 4x4 problems

[MPott227]

Hey I’m new here. My names Matt and I live in Delaware. Let me start by saying I’m not being lazy by starting a new thread on this. I’ve searched and searched the forums. I’ve found plenty of useful information and tried a lot of the things suggested. However, I haven’t found anyone who has went through the same sequence of events as me

I have an 02 limited. I bought it in June and 4x4 worked. In August I discovered pink milkshake (have since replaced trans). One night I was putting my 4Runner on my rollback to take to a friends shop. It was pouring rain and I didn’t feel like winching it. The trans could barely make it up the truck so I figured I’d put it in 4x4 to give it some assistance. 4x4 didn’t work. It did some clunking and banging and then it was as if it was in neutral. I know the pink milkshake should be unrelated but I’m just trying to be detailed in what happened

Had a friend put trans in, somehow forgot to say anything about t case and when I got it back obviously still no 4x4. Still the same problem, I could hear it shift but then it was basically in neutral and would grind/bang when I put it in park

Had access to a free t case, my dad and I put it in and still the same problem. 4x4 engages (or tried to) and truck was basically in neutral

Next thing I did was test the 2 rear sensors on t case, both had continuity
Took motor off of t case and jumped it, it works
When I reinstalled motor on t case I tried to use 4x4, this activated t case motor for a second or two, nothing else seemed to shift or move, truck wasn’t in “neutral” this time but 4x4 didn’t engage and the light flashed for the next week.
Got some more time today and pulled the front diff actuator, jumped it, it works as it should. I also jumped the motor on t case while it was still installed which cured my blinking indicator light
One thing puzzling to me is I reinstalled front diff actuator, applied 12v to move it to the engaged position and driveshaft still spun freely and spinning one wheel did not effect the other
I’m sorry this post is so long and I hope everyone will read it. If I wasn’t clear on anything please let me know

ANY info would be greatly appreciated. Thanks

 

[deves2]

I have a 2001 and a few years ago I had a similar problem. Like you i checked everything and everything as a single unit seemed to work. Problem stayed. I got on this forum and some guy from the midwest chimed in and said it was the front actuator. I told him i checked it and it worked on the bench. he said to get a new one. the cost was almost $300 for a new one so I did NOT get it. For several weeks I again checked everything, all the sensors on trans etc. Out of desperation I bought a NEW front actuator, installed it and my problem was solved. It turned out that the electrical actuator would work fine with no load on it but it would NOT work in the car.
I'm NOT saying that is the fix for you but it worked for me.....good luck

 

[MPott227]

I have a 2001 and a few years ago I had a similar problem. Like you i checked everything and everything as a single unit seemed to work. Problem stayed. I got on this forum and some guy from the midwest chimed in and said it was the front actuator. I told him i checked it and it worked on the bench. he said to get a new one. the cost was almost $300 for a new one so I did NOT get it. For several weeks I again checked everything, all the sensors on trans etc. Out of desperation I bought a NEW front actuator, installed it and my problem was solved. It turned out that the electrical actuator would work fine with no load on it but it would NOT work in the car.
I'm NOT saying that is the fix for you but it worked for me.....good luck

Thanks for the suggestion. I considered replacing the front actuator but am hesitant to do so. Reason being, when this problem began it was as if the truck was in neutral. If the problem was in the front diff, it shouldn’t effect whether the rear is engaged or not

 

[MPott227]

I had little to no hope this would work but I changed front diff fluid because when I pulled the actuator I lost a little oil so since I had no idea if or when it was ever changed I changed it instead of just topping it off. Problem persists

 

[MPott227]

With where I’m at now it seems like the front actuator could be the issue based on everything I’ve read. The thing holding me up on buying a new one is what I said about when this problem started the 4x4 would try to engage and then my 4Runner seemed as if it was in neutral (other than some noise and quite a bang when I’d shift into park). Does anyone have any idea what would cause that? I’m at my witts end with this thing I’d really appreciate any input

 

[phattyduck]

With where I’m at now it seems like the front actuator could be the issue based on everything I’ve read. The thing holding me up on buying a new one is what I said about when this problem started the 4x4 would try to engage and then my 4Runner seemed as if it was in neutral (other than some noise and quite a bang when I’d shift into park). Does anyone have any idea what would cause that? I’m at my witts end with this thing I’d really appreciate any input

That sounds like the transfer case is in "AWD" mode and the front differential is disconnected.

I bet if you look under the truck while you are trying to shift into 4WD, you will find the front driveshaft (from transfer case to diff) spinning and nothing else moving on the truck. Don't shift into park when it is doing that!!

There may be a way to fix the front actuator, or you may just have to fine a used working replacement.

Get the truck up on jack stands and start debugging!

-Charlie

 

[Tinigunner11]

I also had a similar problem like this in my 2000 limited. Transfer case worked just fine but then I replaced the trans and now it's stuck in 4x4/AWD, still searching for the solution also. have you tried jumpering the actuator at the plugs on the transfer case?

 

[MPott227]

That sounds like the transfer case is in "AWD" mode and the front differential is disconnected.

I bet if you look under the truck while you are trying to shift into 4WD, you will find the front driveshaft (from transfer case to diff) spinning and nothing else moving on the truck. Don't shift into park when it is doing that!!

There may be a way to fix the front actuator, or you may just have to fine a used working replacement.

Get the truck up on jack stands and start debugging!

-Charlie

Now it does nothing when I press 4wd. The “neutral” effect is what it did when I first started having issues. But maybe what you’re saying is what was going on and now the actuator is completely dead. I did remove the actuator and jump it and it moved though. But I was told sometimes they work for a bench test but won’t work under load

 

[MPott227]

I also had a similar problem like this in my 2000 limited. Transfer case worked just fine but then I replaced the trans and now it's stuck in 4x4/AWD, still searching for the solution also. have you tried jumpering the actuator at the plugs on the transfer case?

Yea I tried that. It seemed to work

 

[phattyduck]

Yea I tried that. It seemed to work

There are many position switches and actuators to test/check.

The front diff has an actuator and a position switch, the transfer case has an actuator and multiple position switches.

When you say nothing happens, do you mean you don't hear anything happening, or no lights on the dash change or something else? Have you tried both the 4WD button and the center diff lock button?

-Charlie

 

[calimobber]

Ill try and add my experience. So i drove through some water at one point and I believe water got into my transfer case actuator motor and rusted the points so the comp was lost when I tried to shift.

I just got the blinking lights. I pulled the motor from the transfer case and it worked so i cleaned up everything the best i could. once you pull that motor you can loose the proper placement and it can throw everything out of sync.

The 2001/02 have a complex system and rely on sensors from the front diff and the transfer case diff. I ended up giving up and getting a new transfer case and it fixed my issues.

The first thing you can do is Jack up the 4runner so all 4 tires are off the ground and try and find out what mode your vehicle is in. you can start the car and see what spins. Also can manually move the tires to see whats moving. Be very careful and always be safe when running the car off the ground.


You can manually shift the front diff and with it connected and use a volt meter to make sure the sensor it reports the proper signal that it shifted. for 01/02 its 2 of the wires show a completed signal I beleive.

if thats working then you can also manually try and shift the actuator into a set position if its working. Now before the battery is re connected set up the 4x4 system buttons so they match your 4x4 configuration and then hook up the battery.

 

[MPott227]

There are many position switches and actuators to test/check.

The front diff has an actuator and a position switch, the transfer case has an actuator and multiple position switches.

When you say nothing happens, do you mean you don't hear anything happening, or no lights on the dash change or something else? Have you tried both the 4WD button and the center diff lock button?

-Charlie

I’ve tested the two switches near the motor on the t case but no other switches. When I say nothing happens I mean I hear nothing shift. The lights just start flashing. I have tried the center diff button

 

[MPott227]

The first thing you can do is Jack up the 4runner so all 4 tires are off the ground and try and find out what mode your vehicle is in. you can start the car and see what spins. Also can manually move the tires to see whats moving. Be very careful and always be safe when running the car off the ground.


You can manually shift the front diff and with it connected and use a volt meter to make sure the sensor it reports the proper signal that it shifted. for 01/02 its 2 of the wires show a completed signal I beleive.

if thats working then you can also manually try and shift the actuator into a set position if its working. Now before the battery is re connected set up the 4x4 system buttons so they match your 4x4 configuration and then hook up the battery.

Thanks for all your input. I’ll get it on the lift tomorrow and try it out. I really appreciate everyone’s help!

 

[MPott227]

So I have 4wd, sorta. Pulled the front diff again and I don’t think the fork was lined up with the ring it slides. Lined it all up now I have 4wd it just takes a little process. I press the button and the t case shifts, then I have to turn the key off and when I turn it back on the diff actuator shifts. Weird and annoying but it works.

Unfortunately I have a new unrelated problem. Trans whining and has no reverse. Yay