4th Gen 4WD warranty work V6

[Cycle M5]

Hey guys. I need some qualified opinions here.
I have an 08 Sport with 4WD. 4wheel low would not work. It was covered under warranty. Dealership first changed out 4 wheel high actuator. That did not fix it. Then took out the transfer case and changed 4 wheel low actuator.
They gave it back saying the parts and set up are "up dated". When I switch into 4WD hi... it goes into 4WD with the center diff locked. The green and yellow 4WD light flashes constantly. If I press the 4WD diff lock out switch, both lights glow solid. If I hit the diff switch again, the green light stays solid and the yellow one blinks... And the center diff continues to be locked.
The 4WD LOW works very well, but now the 4WD hi only engages with the center diff always locked (meaning very hard to turn on hard surface).

I went back and said that this was not how it was before, and they said it was fine, just an updated system.
WTF. If this repair is a better set up, I'm willing to live with it. But it is now not the stock set up I originally had on this truck.
I'm thinking they got the wrong actuator installed. I believe this because there are so many 4WD versions of this truck on the market internationally.
I'm thinking of going to another dealership, or writing Toyota directly.
Does anyone have any expertise or experience with this kind of repair? Please help.

 

[fdbyrne]

If you can no longer run 4Hi without the differential locked, something isn't right. Remind them that you didn't ask for an 'upgrade' you just asked them to fix what was broken and they failed miserably.

 

[gm350reratliff]

I would make them show you the paper work that says that is now how the 4x4 is supposed to work. I would also get it touch with Toyota on this matter. It doesn't sound right to me. There should be no flashing lights when it use. The flashing lights indicate that the actuators are in between modes.

 

[BlackWorksInc]

Wait, what? There isn't a separate 4Hi and 4Lo actuator unit on an '08... it's all one unit that is bolted to and pinned inside of the transfer case...

I'm confused...

 

[BADCUDA1]

:snacker::snacker::snacker::snacker:

 

[Cycle M5]

Please read again... Both units were replaced. I'm not certain what they did, but I can't believe a dealership would repair a vehicle and return it in this condition. I have been trying to write to Toyota , but their sight won't let me send the message.
I'm going to get another opinion at another dealership.
There are few things I love more than my T4R. The thought of going back to those people frightens me.

 

[LOBO79]

Wait, what? There isn't a separate 4Hi and 4Lo actuator unit on an '08... it's all one unit that is bolted to and pinned inside of the transfer case...

I'm confused...

This guy knows what he is talking about

 

[mrpurplepenguin]

Wait, what? There isn't a separate 4Hi and 4Lo actuator unit on an '08... it's all one unit that is bolted to and pinned inside of the transfer case...

I'm confused...

I'm guessing the first unit replaced was the front diff actuator, then the transfer case actuator pack was replaced next. Just incorrectly worded.

Either way, the 4wd system isn't functioning correctly and there was never an "updated system" that intentionally removed the ability to be in 4wd hi (or lo) without the center diff locked. The shop didn't repair the vehicle correctly, plain and simple.

 

[BlackWorksInc]

Please read again... Both units were replaced. I'm not certain what they did, but I can't believe a dealership would repair a vehicle and return it in this condition. I have been trying to write to Toyota , but their sight won't let me send the message.
I'm going to get another opinion at another dealership.
There are few things I love more than my T4R. The thought of going back to those people frightens me.

I did read it and I am somewhat confused...

(Image Courtesy of http://www.toyota-4runner.org/4th-gen-t4rs/182074-fixing-transfer-case-shift-motor-leak-within.html)

The large black plastic box in the picture is the 4Hi, 4Lo, and CDL (Center Differential Lock) Actuator Assembly. It is a non-serviceable part, you have to replace the entire assembly to fix one actuator (which requires you to split the case open to unpin it from the inside of the transfercase.

So either the dealership replaced the transfercase actuator twice, or they did something else... For the North American market there should be only two actuators for your year; a V8 and a V6 as all US market 4th gens came with only 2 transfercase options based on engine and both had the T3 Torsen center differential with CDL. So you can see why I am a bit confused on what exactly the dealership did to your vehicle...

Post Note-

The only other actuatorthat is pertinent to the 4WD system is if you have a V6 4WD and they decided to replace the ADD (Automatic Differential Disconnect) actuator on the front axle. But that would be for both 4Hi & 4Lo as it connects the passenger's front axle to the differential and transfercase when 4WD is commanded on.

 

[Cycle M5]

Sorry it took so long to respond. Thank you all for your input.
BlackworksInc, thank you for your insight. My original description of what was done was simply a quote of what was said to me. I have photos of the service slip. This should clear up what exactly was done to this truck... The first photo is the service and parts, the second was when I brought it back and they said it was "working ok".
Soooo, I emailed Toyota Corporate with an question about the "updated" 4WD set up currently in my truck. In two days, they called me to get more details. I explained how twice their mechanic "fixed" my 4WD system and how long it took, and how I returned it only to be told it was fixed, which was why I didn't want to go back to that dealership. They sent me to another dealership where I met the service manager. He immediately realized that the system was not working correctly.
He told me that the other dealership service manager was a friend of his and that he wants me to bring it back to straighten out the mess. I said "No offense, but they had three chances to straighten it out and they didn't get the job done." He reassured me that it will be done right this time.
So next week Im going back there again. I now wish I had gone somewhere else, or at least did my homework on the track record of their service department.
Any thoughts, any one? After reading your post, I'm thinking the Center Diff Actuator was not wired in properly or is not working all together. It won't even come out of 4WD Low if the Center Diff Lock is engaged. I'm not sure whether or not that is normal.... but it doesn't seem normal.

 

[Cycle M5]

So, this is how it ended.
I went back to the original dealership. They had me speak to their senior mechanic, who was very familiar with the 4WD set up's in 4Runners. He did agree that the system was no operating normally.
The service manager hooked me up with a loner car. That was nice. They finally were seeing the light here about the transfer case. And, the service manager could probably see in my eyes the pounding they were about to get on Facebook.
At the end of the second day, my truck was finished. A lead or a switch at the end of one of the actuators was damaged during the previous repair, and it was wreaking havoc on the computer that controls the 4WD. They replaced it after they pulled the transfer case apart or the differential apart, or whatever.
It now works fine and I now have many new parts in my truck. My confidence has been restored somewhat..... at least enough not to go public with my experience.
I hope this will be helpful to someone someday that has the same situation.