2002 transfer case actuator motor, can it be fixed?

[theriddler]

I've read that you have to remove the transfer case to replace the 4x4 actuator, but I would say that most problems that come from this are due to the electronics and not the mechanical actuator that goes inside the transfer case.
Page 2 of this thread got me curious:
https://www.yotatech.com/forums/f2/01-4runner-wont-disengage-4wd-294025/index2.html
I removed the cover from mine yesterday to inspect it and it looked fine for the most part. There was a yellow looking grease inside that was starting to harden up so I took some contact cleaner and cleaned everything out. I put some lithium grease on the worm gear and actuator gear (still on the transfer case shaft) and put a light coat of dielectric grease on the electrical contacts. I cleaned the rubber gasket, reinstalled the metal bushing in the plastic cover, and replaced the 3 bolts that attach it. That's really about it, a 10mm socket is all you need and it's even accessible without a lift or floor jack.

I guess i'm not seeing what makes these things $950 from Toyota and why there aren't any aftermarket replacements out there. The motor that turns the worm gear may be bad on mine and I'm not having any luck finding a replacement for a decent price.

 

[Streetrod19772000]

Stranger case

They can easily be fixed without removing transfer case.

 

[derpiful]

Mine went bad not too long ago, and I tried and tried to revive the motor similar to what you've done. No matter what I tried, the motor was just dead.

You can occasionally find them in junkyards or someone parting out on Craigslist, but most I found the person didn't want to separate it from the TC,. which is fair. I also found a few ready-to-ship on eBay for about $250- this is the option I ended up going with to save time.

I agree, it's expensive for what it is, but this really was the best option I could find.

Good luck!