Mtns_Yo
New member
I plan on doing this as well, as my front actuator tested fine. Really hoping I can find a tcase actuator soon.
4wd not engaging in my 2001 4runner
- Thread starter ToyotaJoe01
- Start date
I plan on doing this as well, as my front actuator tested fine. Really hoping I can find a tcase actuator soon.
I would definitely make sure that you are applying power to the right pins first (no offense but better safe than sorry), and then yeah your actuator is probably dead. I would for sure check junkyards first - you can usually buy a whole t-case with an actuator for somewhere around the 300 range rather than just a "new" actuator
Mtns_Yo
New member
Yeah, no offense taken man. I am not too good with this electrical troubleshooting but I fell pretty confident I tested the correct pins. I watched that video added a couple post back at least a dozen times and followed the FSM.
Good news, junkyard just received an 02 in town and will have the tcase out in a day or two. they quoted me $200 for the whole tcase. :rockon:
Mtns_Yo
New member
Update
Got my donor Tcase yesterday and swapped the Tcase actuators and still blinking lights. Nothing was engaging, no sounds from both front and tcase actuators.
4WD still not working!
YouTube
Did some more trouble shooting today, and guess what? No more blinking lights. Both front and rear actuators are working. AWD, 4H, and 4L are back!
what I did today. And what worked for me.
I don’t have any pictures of the front actuator, I already put my skid plates back on and these 4Xinnovation skids are heavy and I don’t want to pull them off again, I broke one of the tack welds on a nut and had to improvise.
The very first thing I did was test the new actuator by applying power to the actuator and making sure it was spinning in both direction. I did this with the actuator off the tcase. I simply put (+) on terminal 2 and (-) on terminal 6 and vice versa to get it to spin the other way. If you don’t have any aligator clips you should get some. They make this process a breeze. Harbor freight has them for like $5.
Once I felt comfortable the donor actuator worked properly, I proceeded to remove the old one and install the donor one.
Step 1.
Removed actuator from donor tcase. Remove cover by removing the breather hose, in clip the wiring harness and 3) 10MM bolts circled in picture.
Step 2.
Pull the cover off, and remove the gear inside. This will allow you to remove the actuator housing without any trouble.
Step 3.
Remove the actuator housing. 3) 12MM bolts circled in picture.
Once that is removed this is what it’ll look like.
Step 4.
Pull the rod in an out a couple times. Then leave the rod all the way out, that should be 2WD.
Step 5.
Clean 4WD Switches in new tcase housing. You’ll need a 27MM deep socket to remove them. I used some MAF sensor cleaner. Check them for continuity. If they test good, proceed.
Clean new actuator housing, I again used some MAF sensor cleaner.
Clean all electrical connections with some electronic cleaner.
Step 6.
Reassemble actuator housing. Slowly work the actuator assembly back on and tighten the 3) 12MM bolts. Remember to make sure the rod is pulled all the way out in the 2WD position before reassembling the the actuator.
Step 7.
Reinstall the two 4WD position switches using a 27MM deep socket.
Step 8.
Install the actuator gear, make sure the 3 prongs are in the 2WD position.
It should be close to this position.
Step 9.
Attach the actuator housing. Tighten 3) 10MM bolts and attach breather hose.
Step 10.
Make sure your A.D.D. is disconnected. You’ll need to remove the wiring harness on the front actuator and use your alligator clips and apply (-) to terminal 2 and (+) to terminal 6 and vise versa to connect it. I did this a few time to ensure everything was working properly. You’ll be able to hear it connect and disconnect. On mine I could tell it was disconnected because I could spin the front driveshaft by hand.
Step 11.
Drive around for a while before trying to engage it. Then engage AWD, 4H, and 4L in that order.
This is what I did and worked for me. Hope this helps someone!
4WD WORKING!
YouTube
Got my donor Tcase yesterday and swapped the Tcase actuators and still blinking lights. Nothing was engaging, no sounds from both front and tcase actuators.
4WD still not working!
YouTube
Did some more trouble shooting today, and guess what? No more blinking lights. Both front and rear actuators are working. AWD, 4H, and 4L are back!
what I did today. And what worked for me.
I don’t have any pictures of the front actuator, I already put my skid plates back on and these 4Xinnovation skids are heavy and I don’t want to pull them off again, I broke one of the tack welds on a nut and had to improvise.
The very first thing I did was test the new actuator by applying power to the actuator and making sure it was spinning in both direction. I did this with the actuator off the tcase. I simply put (+) on terminal 2 and (-) on terminal 6 and vice versa to get it to spin the other way. If you don’t have any aligator clips you should get some. They make this process a breeze. Harbor freight has them for like $5.
Once I felt comfortable the donor actuator worked properly, I proceeded to remove the old one and install the donor one.
Step 1.
Removed actuator from donor tcase. Remove cover by removing the breather hose, in clip the wiring harness and 3) 10MM bolts circled in picture.
Step 2.
Pull the cover off, and remove the gear inside. This will allow you to remove the actuator housing without any trouble.
Step 3.
Remove the actuator housing. 3) 12MM bolts circled in picture.
Once that is removed this is what it’ll look like.
Step 4.
Pull the rod in an out a couple times. Then leave the rod all the way out, that should be 2WD.
Step 5.
Clean 4WD Switches in new tcase housing. You’ll need a 27MM deep socket to remove them. I used some MAF sensor cleaner. Check them for continuity. If they test good, proceed.
Clean new actuator housing, I again used some MAF sensor cleaner.
Clean all electrical connections with some electronic cleaner.
Step 6.
Reassemble actuator housing. Slowly work the actuator assembly back on and tighten the 3) 12MM bolts. Remember to make sure the rod is pulled all the way out in the 2WD position before reassembling the the actuator.
Step 7.
Reinstall the two 4WD position switches using a 27MM deep socket.
Step 8.
Install the actuator gear, make sure the 3 prongs are in the 2WD position.
It should be close to this position.
Step 9.
Attach the actuator housing. Tighten 3) 10MM bolts and attach breather hose.
Step 10.
Make sure your A.D.D. is disconnected. You’ll need to remove the wiring harness on the front actuator and use your alligator clips and apply (-) to terminal 2 and (+) to terminal 6 and vise versa to connect it. I did this a few time to ensure everything was working properly. You’ll be able to hear it connect and disconnect. On mine I could tell it was disconnected because I could spin the front driveshaft by hand.
Step 11.
Drive around for a while before trying to engage it. Then engage AWD, 4H, and 4L in that order.
This is what I did and worked for me. Hope this helps someone!
4WD WORKING!
YouTube
Last edited:
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