4wheel Drive not engaging properly

[TRevsRunner]

My 2002 4runner Sport Edition's 4wheel drive is not engaging properly. Seems like a common issue on these and looking for some advice as to what the problem may be. I took it to a shop and had them take a look at it on the lift and I was worried that the transfer case would have to be rebuilt. The technician pulled up the service bulletin and thought it could be either the 4x4 position switch, actuator assembly, or 4x4 indicator light which also has to do with the position switch. So what's happening when I press the 4hi button while moving it will not engage, the light will just keep blinking. However I can get it to engage if I put it in neutral while stoped as long as the center diff is unlocked 4 wheel will work fine. If I engage it with the center diff locked it engages but doesn't seem to engage properly. It acts as if the front and rear diff are not working together and binds up. Something is defiantly wrong. Then it is very hard to get out of 4wheel but will come out if you back up, slam it in gear or try different ways and it will pop out. What do you think? I've read many threads but non seem to be acting similar to mine. Where should I start?

 

[jgue467]

Right turns

Have you had your truck very long? Know its history as far as 4wd (used often or not)?

Well anyway your symptoms are typical of non or very little use. The manual says to use the 4wd weekly for 10 miles at least to keep it all nice. It also says if the lights blink, to stop, reverse then forward, but this works better.

So here's what to do. Engage/disengage 4wd just before a right turn. Can't explain why but this gets the mechanism to quickly engage/disengage.

Now we all know locking the center diff is Only for loose dirt/mud/sand conditions and cannot at all be done on a hard surface like asphalt/concrete.

If you haven't yet, change the fluids (and lube your driveline) but the main thing to get it all working as it should it to use it regularly. Mine did the same thing for about 6 months then finally started working rather seamlessly and will engage/disengage going straight or whatever.

So don't let somebody take your for $$$ to repair what doesn't need repair-they are guessing, arseholes.

Luck! :banana:

 

[TRevsRunner]

Right turns

I bought this truck this February and it appears that it has been sitting for a while. It's has very low miles and previous owner mentioned he took it off road once

 

[Dawgz]

What's the top speed in 4wd mode with center not locked?

 

[afg10000]

Just an FYI. If you do end up needing the actuator switch, don't get the Dorman one. I gots it form O'reilly's a few months ago and recently found a diff leak. It was coming from the top of the switch. Going to pick up a OEM one from the dealer in the morning. I'll get you the part# if you end up needing it.

 

[TRevsRunner]

Thanks for the tips, I am going to work on that. As far as top speed in 4wheel I'm not sure. Have been afraid to use it because I was worried of something internal being wrong.