4WD Transfer Case Overhaul

[Radial GT]

Hello there,

My problem is that my 4lo is not working. After reading about this, it appears that this is a common problem. So when I replace the acuator, I would also like to replace all the seals so I do not have to worry about this thing again.

Has anyone on this forum performed this overhaul. I have looked at the FSM's .pdf file on how to perform this repair and it looks fairly straight-forward. I was curious if someone has blazed trail on this yet? I have searched and all I find is people talking about having a shop do the work for them. I am mechanically inclined and want to perform this repair myself.

Thanks!

 

[settytb]

You would be the first I've heard of. Do it!!! Make sure to take pics/video of the process.
Good luck!

 

[simple]

Hello there,

My problem is that my 4lo is not working. After reading about this, it appears that this is a common problem. So when I replace the acuator, I would also like to replace all the seals so I do not have to worry about this thing again.

Has anyone on this forum performed this overhaul. I have looked at the FSM's .pdf file on how to perform this repair and it looks fairly straight-forward. I was curious if someone has blazed trail on this yet? I have searched and all I find is people talking about having a shop do the work for them. I am mechanically inclined and want to perform this repair myself.

Thanks!

Dude. Have you troubleshot at all? My actuator was frozen and I sat in a parking lot for a half hour watching the 4lo blink. Then I tried cycling back and forth between 2-4hi-4lo over and over again giving the 4lo just a few flashes. That worked for me. And it still is fine. I just don't want your first course of action to be taking apart the TC

 

[Radial GT]

Dude. Have you troubleshot at all? My actuator was frozen and I sat in a parking lot for a half hour watching the 4lo blink. Then I tried cycling back and forth between 2-4hi-4lo over and over again giving the 4lo just a few flashes. That worked for me. And it still is fine. I just don't want your first course of action to be taking apart the TC

I have messed with it for maybe a total of 10 minutes. I figured that if it had not un-f-ed itself in 10 minutes it wasn't going to. Perhaps I will performed all kinds of stop, go, neutral, center diff lock for 30 minutes to see if I can't persuade it to move. I bought this Runner from a woman who I am certain never even used the 4lo. She owned this truck for 80K miles, so I am thinking it is going to be VERY stuck.

Worst case scenario is I have to buy a couple of special tools to overhaul this thing. It will still be cheaper than the $3,000 dealer quote. I will keep this thread up to date if I pull the trigger on it. Next summer..

 

[dustybaseball]

Radial GT,

Have you completed your transfer case overhaul? If so, can you post pictures of your actuator? My actuator locked up so I have taken it off and apart and put the gears back as they should be. Only thing is, while doing all of this, the timing has gotten off. Do you happen to know what I am talking about and how to fix it?

Thanks,
Dusty

 

[talonjade]

~Ditto

 

[bytemaster0]

Radial GT,

Have you completed your transfer case overhaul? If so, can you post pictures of your actuator? My actuator locked up so I have taken it off and apart and put the gears back as they should be. Only thing is, while doing all of this, the timing has gotten off. Do you happen to know what I am talking about and how to fix it?

Thanks,
Dusty

I can help you with the timing. I had to figure it out myself as well. Very tricky, but it CAN be done (I had to do it.) I ended up replacing the actuator at the dealer after all that work, but maybe I can give you a helping hand. Let me know where you are, and I'll see what we can figure out from there.