97 5speed 4wd not working

[brend2b]

Just in time for snow, my 4wd decided to stop working. I have the 4wd without the push button selector. I narrowed the problem down to the 4wd switch on the top of the transfer case. No matter if the transfer case is shifted into 4wd or not, there is no continuity. To see if I could get the ADD control system to function, I temporarily put a toggle switch in place of the switch on the transfer case, and i can get the ADD system to engage, and the dash light to come on.

I lifted the car off all four tires to check if the front wheels spun, and no matter if shifted into 4wd high or 4wd lo, the front drive shaft does not spin. It worked properly a week ago, and I cant see why the transfer case would suddenly stop working. Any input would be much appreciated. thanks

 

[blonde1boarder]

Mine is intermittently having the same problem and I have a 97 5 speed also so I'm hoping you find a solution to this.

 

[3rdgensr5]

Same problem here as well, 99 5 speed, only works when it wants to. it sounds like a switch to me, the 4wd operates fine.

 

[brend2b]

I've ruled out it being any switches by going through the entire ADD system. The front axle and ADD system function properly. The transfer case physically doesnt transmit power to the front drive shaft. As far as I can tell its a problem with the transfer case.

 

[Doc2012]

You have a manual transfer case, correct?

Have you heard anything pop or snap? The only reason that it would be doing that is if you broke a gear or chain in the transfer case, and THAT you would know.

Even though your ADD system works fine, there are still sensors on the t-case that actuate that system. If those are bad, you won't get 4wd.

Do you have a center locking diff on that thing? I'd assume not, because you said it's a 5 speed.


Scroll down to the part where I explain how to convert the ADD diff to a manual, then do the manual hub swap, or just put a fully manual t-case in there, then run the ADD to a set of your own switches, or do both the manual hub and transfer case like I did. Gets rid of all that crap.

That should take care if it all.

http://www.toyota-4runner.org/3rd-gen-t4rs/127367-docs-mod-thread.html

 

[brend2b]

I don't have the center locking differential with the push button control, just the manual one with the "J" shift pattern. As far as I could tell by reading the fsm and checking the transfer case, there is only one sensor on the transfer case that tells the ADD system the transfer case is in 4wd.

When I checked the continuity of that switch when changing from 2wd to 4wd, there was no change leading me to believe the switch was bad. When I put the ADD system on a switch instead of that sensor, I could connect the front diff, and have the dash light come on, but it is still not in 4wd as the front diff is getting no power.

The one thing that led me to believe it was a problem in the transfer case was that when all 4 tires were off the ground, the front drive shaft would not even spin when the transfer case was shifted into 4wd.

Even if this switch is bad, when in 4wd the front drive shaft would still spin correct?

 

[Bishard]

Try switching vac lines on add solenoid switches. Worked for me until I got new switch from junk yard. FYI switches from 2nd gen 3.0 works on 3rd gen 2.7L