4x4 issue, any ideas?

[tashtego]

Hi Everyone,

I am based in Malawi, Africa, for work and I have been driving Hilux Surfs (what the 4Runner is called here) since 2005, I am a big fan.

I currently drive a 1996, 3rd Gen Surf, Auto, KZN 185 (diesel engine, kz-te, 3.0L).

I have often used the info on here and decided it's time to join.

I have a transfer case/4x4 issue.

Mine is the version with the Multimode 4x4, where you press the button and get AWD, then manually select on the lever to shift to H4 (lock centre diff) etc.

Basically I lost drive when I engage 4x4 on the button.

So I put the truck on axle stands, got a friend to sit in and operate the system, and this is what I found out:

as the button is pressed in, for AWD, you hear the usual clunk, the 4x4 dash light display comes on, the front diff engages very briefly, and the front wheels start to spin. However after a couple of seconds they stop, and so do the rear wheels, so drive is lost to both. You hear a whine that seems to go up as you rev…

Locking the centre diff with the lever (H4 position) restores drive, but only to the rear drivetrain.

As you disengage the button, there is a lot of metal on metal noise, and then rear wheel drive is restored.

The local Toyota dealer has tied to download the manual, but since it is a Japan model, the repair manuals that Toyota can access are in Japanese.

They also looked at the US 4Runner manuals, but it appears the 4x4 system is different, as it does not seem to have the same multimode system as mine, where you can have 4x4 without locking the centre diff, and then lock the centre diff on the lever. Maybe that same system came out in US after 1996?

Thank you for any input.

 

[phattyduck]

The system on your Surf most closely matches what was available on the '99/'00 4Runner Limited.

It sounds like the center differential is broken or possibly the front drive output (chain, etc.).

-Charlie

 

[dirteater4]

Yank out the source of the "metal" noises and open it up. Start with the transfer case.

 

[tashtego]

Thanks guys,

I am looking at some online pictures of the transfer case set up to see what I can do..

Cheers

 

[tashtego]

After discussions with my mechanic , we have realised we need the pages from the manual with the instructions for inspection of the transfer case , with diagrams etc. It's the multimode version with lockable centre diff, I think it came out in US in1999.

The local Toyota garage can only access them in Japanese .

Has anybody got a copy of the English version?

Many thanks

 

[jgue467]

After discussions with my mechanic , we have realised we need the pages from the manual with the instructions for inspection of the transfer case , with diagrams etc. It's the multimode version with lockable centre diff, I think it came out in US in1999.

The local Toyota garage can only access them in Japanese .

Has anybody got a copy of the English version?

Many thanks

https://drive.google.com/open?id=0B20d86M4DqTrVU5wUHhyUVN4OWM

 

[tashtego]

https://drive.google.com/open?id=0B20d86M4DqTrVU5wUHhyUVN4OWM

Thank you jgue467, this looks great, I will definitely need this at some point.:happy:

The problem with this manual is that I cannot seem to find the type of transfer case set up that is in my truck, the multimode one. The manual refers to the VF3AM transfer case, with only L4/N/H positions.

While mine is the one in the first pic in this thread, with H2/H4, H4L, N, L4L

Apparently it came out in US for the 99-00 limited edition.

http://www.toyota-4runner.org/3rd-g...rs-3rd-gens-transfer-case-awd-multi-mode.html


Cheers

 

[phattyduck]

The "left" two positions are not a mechanical connection in the transfer case, it only operates an electric switch. Mechanically, the later multi-mode case and the early multi-mode case should be very similar mechanically.

I only have a physical copy of the '99 manual, but that doesn't really help you on the other side of the world...

-Charlie

 

[tashtego]

Hi Charlie,

if the transfer cases were mechanically the same , that would be good news for me, I guess.

Would it be possible for you to check for me if your manual covers both pages multimode and normal transfer cases? Like , the the disassembly and reassembly instructions, are they two different sets?

I'm thinking I could always try and buy the manual in the US through Amazon or similar.

Cheers

Fabrizio

 

[phattyduck]

Hi Charlie,

if the transfer cases were mechanically the same , that would be good news for me, I guess.

Would it be possible for you to check for me if your manual covers both pages multimode and normal transfer cases? Like , the the disassembly and reassembly instructions, are they two different sets?

I'm thinking I could always try and buy the manual in the US through Amazon or similar.

Cheers

Fabrizio

Yes, the US manual covers both types of transfer cases. They are in separate chapters.

-Charlie

 

[tashtego]

Thank you, I will look at buying it online.

Cheers

Fabrizio

 

[tashtego]

I have just bought this downloadable manual for the 1999 3rd Gen:

https://www.emanualonline.com/Cars/...ner-Service-%2526-Repair-Manual-Software.html

I have looked at the Transfer case chapter but it only seems to have the traditional one with 3 modes, I cannot find the multimode...Do you know what the abbreviation is to get to the right chapter?

Cheers

 

[phattyduck]

The transfer case you are looking for is the VF3AM. The chapter heading is "TR" but I'm not sure what it would be called on your digital copy...

Another option is to download directly from Toyota (it would still be the US version, but you know it will be correct). You can get a 3-day pass to the Toyota TIS system and download what you need.

-Charlie

 

[tashtego]

Hi Charlie,

Thanks for this info, very grateful.

So the VF3AM transfer case is the same for the multimode 4x4 surfs?

The guys at Toyota here saw that the connector socket on my actuator was different from the one in my car (6 pins in a row, while mine has 2 rows of 3 or 4, something like that) and they deduced that the transfer case must be different...

Thanks again,

Fabrizio

 

[tashtego]

Here is the pics, the connector from the manual versus the connector in my actuator, held by the Toyota mechanic.

This is what made them think that it's a completely different transfer box...