4x4 disengage problem

[jstevenj]

I have been trying to help my brother fix his 96 Limited Edition 4runner. At first it would not engage 4x4. We checked and found a bad switch on the transfer case actuator motor. Not it will go into 4x4 but will not disengage from 4x4. With the vehicle not running but with the key on we can hear the actuator motor run when pushing the button on the hi/low shift lever. I assume by this that the motor is functioning correctly. We did manage to back up a few yards one time and it came out of 4x4. Then we engaged it again and it has yet to come out of 4x4. I even backed up the road 200 yards or so.

We have also checked the front diff engaged switch and front diff vacuum lines and vacuum actuator valves. All seem to be working correctly.

This is a hunting truck and it sits with no use a lot of the time so I am wondering if something is just not moving freely enough to disengage. Also wondering if there is a way to "time" the transfer case actuator motor thinking it could be moving almost far enough to disengage and we just got lucky the first and only time it disengaged.

Any help would be greatly appreciated.

 

[USMC0351]

I have been trying to help my brother fix his 06 Limited Edition 4runner. At first it would not engage 4x4. We checked and found a bad switch on the transfer case actuator motor. Not it will go into 4x4 but will not disengage from 4x4. With the vehicle not running but with the key on we can hear the actuator motor run when pushing the button on the hi/low shift lever. I assume by this that the motor is functioning correctly. We did manage to back up a few yards one time and it came out of 4x4. Then we engaged it again and it has yet to come out of 4x4. I even backed up the road 200 yards or so.

We have also checked the front diff engaged switch and front diff vacuum lines and vacuum actuator valves. All seem to be working correctly.

This is a hunting truck and it sits with no use a lot of the time so I am wondering if something is just not moving freely enough to disengage. Also wondering if there is a way to "time" the transfer case actuator motor thinking it could be moving almost far enough to disengage and we just got lucky the first and only time it disengaged.

Any help would be greatly appreciated.

Not to be a negative nancy, but you may wanna ask the guys over in the 4th Gen section. This section is for 96-02 T4Rs. Sorry I don't have any experience with that type of issue, but just a heads up. Good luck with the fix

 

[jstevenj]

Sorry it is a 96 model, not 06 model.

Not to be a negative nancy, but you may wanna ask the guys over in the 4th Gen section. This section is for 96-02 T4Rs. Sorry I don't have any experience with that type of issue, but just a heads up. Good luck with the fix

It's a 96 model, not 06, sorry

 

[jgue467]

Guesing you've tried general maintenance, like changing the front/center diff fluids? Mine used to be difficult to engage/somewhat to disengage. My main 'trick' to engage it was to depress the 4wd button just before a right turn, it would quickly engage/disengage that way. Then after regular use (few miles a week), it started working as it should, so regular use is a plus.

If its for hunting and not used alot, why not leave it engaged all the time? Luck! :banana:

 

[jstevenj]

Guesing you've tried general maintenance, like changing the front/center diff fluids? Mine used to be difficult to engage/somewhat to disengage. My main 'trick' to engage it was to depress the 4wd button just before a right turn, it would quickly engage/disengage that way. Then after regular use (few miles a week), it started working as it should, so regular use is a plus.

If its for hunting and not used alot, why not leave it engaged all the time? Luck! :banana:

Haven't changed the fluid in the diff. And yes it sits a lot. He has only used it one hunting season and its been pretty much sitting since. He discovered during hunting season that is was not going into 4x4 but the new switch on the t-case fixed that. Sounds like we may just have a sticky slide on the diff coupling.

We haven't tested the vacuum valves with a vacuum source but I did apply 12V to each of them and they made a click - by that I am assuming the solinoid spool i shifting properly.