2004 4WD clunking issue

[Pintlar Tactical]

So I am a 3rd gen owner but my brother has a 2004 4.7 V8 4wd and experienced the following:

1. All was good until we parked to air up. He tried to put it into 4WD DRIVE and all you heard was clanking and clunking.

2. He could not put it back into park or find any gear.

3. Press the center diff lock button and he was able to drive it home.

4. There was a strange burnt smell at times around his truck. Could not pin point where it was coming from.

Appreciate any input. Even now if he desects center diff lock he gets the clanking noise and cannot drive.

So, any ideas what is wrong and is there a huge issue driving with the center diff lock engaged?

 

[grave]

3. Press the center diff lock button and he was able to drive it home.

4. There was a strange burnt smell at times around his truck. Could not pin point where it was coming from.

Appreciate any input. Even now if he desects center diff lock he gets the clanking noise and cannot drive.

So, any ideas what is wrong and is there a huge issue driving with the center diff lock engaged?

 

[wmmcdnld]

So I am a 3rd gen owner but my brother has a 2004 4.7 V8 4wd and experienced the following:

1. All was good until we parked to air up. He tried to put it into 4WD DRIVE and all you heard was clanking and clunking.

2. He could not put it back into park or find any gear.

3. Press the center diff lock button and he was able to drive it home.

4. There was a strange burnt smell at times around his truck. Could not pin point where it was coming from.

Appreciate any input. Even now if he desects center diff lock he gets the clanking noise and cannot drive.

So, any ideas what is wrong and is there a huge issue driving with the center diff lock engaged?

Is this a new problem or did he just pick up the truck? When I first got my 4runner it was probably years since someone put it in 4wd. I had to sit in neutral, change to 4hi and just chill there for like 30-45 seconds before the actuator would eventually figure it out. After driving around in 4wd once a week for awhile the actuator smoothed out like butter.

 

[Pintlar Tactical]

Is this a new problem or did he just pick up the truck? When I first got my 4runner it was probably years since someone put it in 4wd. I had to sit in neutral, change to 4hi and just chill there for like 30-45 seconds before the actuator would eventually figure it out. After driving around in 4wd once a week for awhile the actuator smoothed out like butter.

This is a new problem. He has had it for about 5 years.

With the center diff lock off he cannot find any gear or even put it in park. Trying to put it in reverse or 4D causes loud clunking noises.



With the center diff lock engaged everything sounds and feels normal.

Also, I am pretty sure his truck is full time 4WD.

 

[Pintlar Tactical]

Guess I missed the point?

 

[RobD]

The V8 is full-time four wheel drive. Depending on what article you read, it biases power front/rear roughly 40/60, but can split it 50/50 when the rears start to slip more. When he tried to put it into 4 wheel drive, you must mean 4 low, because there are only two settings on the shift knob: 4H and 4L. It sounds like the actuator has become stuck. I would search the threads on here for advice on tapping the case to unstick it.

And yes, driving with the center diff locked on good roads should be avoided. There will be a lot of stress put on it.