95 4Runner help - Oil leak and ADD wiring

[pcola4runner]

I bought a 95 4Runner 4WD, 3.0, 5 speed for $800 to park and use at my hunting camp. Poor thing was from up North and rusted out fairly bad. So far I have made the following modifications / repairs:

New Radiator, hoses, thermostat, 2" ball joint spacer kit w/rear coils, new shocks all the way around, a lot of metal cut and a lot of attempted rust proofing, 1.5" wheel spacers and some used 32 x 11.5 x 15 tires.

Engine runs fine and transfer case seems to engage fine. I am down to a couple of issues that I need help with:

1) I have an oil leak. Seems to be coming from front of transfer case, but looks / feels like engine oil.

2) No 4WD light / No 4WD - Transfer case engages, I have vaccum, I found a broken connection to a plug on the back passenger side of transfer case that had two wires running to it. These wires have been sheared off to short to repair... Any ideas???

Thanks in advance. I am brand new to the sight and this is my first 4WD project.

 

[Hyde802]

Could the oil leak be your valve covers (know problem on the 3.go)?

Ive never dealt with fixing the ADD just replacing it...so on that note.. get some manual hubs and lock the shifter fork in place ( or replace with a non add axle tube) Then there isnt any wiring or vacuum to deal with, just lock the hubs and go.

 

[pcola4runner]

Thanks... I think I will go the manual hub route. I've seen this advice given more than once while researching the issue.

 

[Doug371]

ADD relay should be right above gas pedal. Hold and feel for clicking when shifting between 2 and 4 wd. 2 black and red wires should be hot w/key on run. Light green when powered activates unlock VSV(2Vacuum switchs located at rear of right inner fender). Dark green w/stripe?(dont have schematic handy)on end w/one of b/r should activate Lock vsv. Check both for power and vacuum in and out. recommend double check color code on wiring.

 

[pcola4runner]

If I posted this correctly... Here is a pic of what I have been able to trace... This is taken from the passenger side looking up toward rear of transfer case. Two wires have been sheared from plug on top of tranfer case. Thinking it may be easier to put hose clamp on locking fork than to get at this plug....

 

[fourwd1]

That switch completes the circuit to the 4WD light (along with the switch on the ADD actuator) and it energizes the ADD relay. Short the 2 wires together and see if it starts working.

 

[pcola4runner]

Ok. I shorted he two wires... I could hear a "clicking" sound on top of transfer case when I did. Still no 4wd light and not sure if it's engaged? Should I have a light or am I just tricking the relay by shorting the wires? Thanks for the help!

 

[fourwd1]

The relay clicking shows it's working, which it needs to do to activate the LOCK vacuum solenoid valve (VSV). The VSV then moves the actuator to lock the axle. That in turn closes another switch which would make the 4WD light illuminate.
Either the front axle isn't locking (VSV, actuator, or vacuum problem) or the switch/wiring has a problem.

 

[pcola4runner]

Thanks for the help fourwd1! I went back and checked the connector on the ADD accuator and repaired another bad wire. Bingo.... Green 4WD light and front axles engaged.

 

[fourwd1]

Glad I could help.