4wd Lights Flashing w/ Damaged Diff Wiring

[SeaDug]

First off, I apologize for my longwindedness but I am tired and angry.

I just got my 2002 back from the shop for an elocker swap. Would have done it myself but just can't with the circumstances in life right now. They swapped in a front diff and rear axle out of a 96. All was well until I tried to turn on 4wd on Saturday to test it. The lights were flashing and wouldn't engage 4wd, whatever, probably the tcase sensors, I'll fix them Monday. Just got under it today to fix it and found some sort of disconnected wiring harness mangled around the steering shaft. Looks like it was from the new front diff, as there was a breather tube taped around it.

It looks like this might have also damaged my steering rack, as there was quite a bit of fluid under the truck that seemed to have come from where the shaft meets the rack(Pics 4/5) and I had heard a loud pop while turning earlier today.

Along with this I found a different wire on the passenger side, near the steering rack, It also looked like it came from the diff.

I'll be bringing it back to the shop and having them fix it, is this disconnected wiring what caused my issue with the 4wd lights?

Thanks for any help, really pissed right now.

 

[APhelps]

You shouldn't need to touch the steering rack to remove/re-install the front diff, in fact it doesn't help you at all with doing the job.

If memory serves me correctly that connector isn't for the front diff (not sure what its for, right at the moment). Likewise that isn't the breather, its a vacuum hose that should be routed to the front diff actuator.

You could turn your 4runner on and click the 4wd button to see if the front diff actuator is working, you'll hear a noise and it should lock the front driveshaft.

 

[SeaDug]

You shouldn't need to touch the steering rack to remove/re-install the front diff, in fact it doesn't help you at all with doing the job.

If memory serves me correctly that connector isn't for the front diff (not sure what its for, right at the moment). Likewise that isn't the breather, its a vacuum hose that should be routed to the front diff actuator.

You could turn your 4runner on and click the 4wd button to see if the front diff actuator is working, you'll hear a noise and it should lock the front driveshaft.

The diff is already installed. And that makes sense, as 4wd hasn't worked for a few days now.

 

[phattyduck]

01/02 front diffs are electrically actuated, so that probably is the front diff plug. If that isn't working, you won't have 4WD and will get the flashing lights on the dash. (the flashing lights are basically the warning that you aren't yet in the mode you have selected)

Trace those oil splashes up front and see where they are coming from. It isn't clear from your pics, really where it is coming from. You may need to clean it up and go for a drive to track it down. (though it could be a disconnected front diff breather, since the rest of the work in that area is suspect)

-Charlie

 

[SeaDug]

01/02 front diffs are electrically actuated, so that probably is the front diff plug. If that isn't working, you won't have 4WD and will get the flashing lights on the dash. (the flashing lights are basically the warning that you aren't yet in the mode you have selected)

Trace those oil splashes up front and see where they are coming from. It isn't clear from your pics, really where it is coming from. You may need to clean it up and go for a drive to track it down. (though it could be a disconnected front diff breather, since the rest of the work in that area is suspect)

-Charlie

Thanks, that's what I wanted to hear. I assume its the breather, but it doesn't have that horrible gear oil stench.