Need Help: Transfer Case Problems!

[Volley]

Hi all,

I am tying to find some information fairly quickly for a friend who's truck kicked the bucket at mechanic's.

It is an 05 V8 w/ full-time 4WD and 205K miles. She had been been complaining of a noise and tried to put it in 4LO the other day, it made a terrible noise so she put it back in 4HI. Took it to the shop today, they were troubleshooting and they put it in 4LO and now can't get it out of 4LO. Shop is telling her she needs a new transfer case ($1100 used w/ 77k miles) plus labor. That seems steep to me. Thoughts?

Is there something else that is could be instead of a whole new transfer case? Any help on getting it out of 4LO?

Thanks!

 

[ARunner]

Sounds like the transfer case actuator is a goner. Common due to non-use. Safest bet is to rap on it with a hammer from beneath while the other person is inside trying to shift back to high range. Otherwise, you can buy a new actuator for about 800-900. Removal of the transfer case is required to install it, unfortunately. I have a friend with a similar issue -related to the center differential lock.

 

[Volley]

Darn it!

Thanks for the reply

 

[Slowgoat]

Got mine unstuck by undoing the bolts on the actuator enough to give me some play, (1-2 mm only!!!) and then GENTLY tapped it with a rubber mallet while someone in the cab toggled the switch back and forth in neutral.

Gummed up actuators are pretty common, but being stuck in 4 lo would suck. Hope you get it.

From what little I know about this, there is a way to get the actuator unstuck once you go through all the trouble of getting it apart:

http://www.toyota-4runner.org/4th-gen-t4rs/182074-fixing-transfer-case-shift-motor-leak-within.html

Or without removing the actuator from the t-fer case (have no idea if this worked, but he is super careful and it seems legit. I personally wouldn't try it):

http://www.toyota-4runner.org/4th-gen-t4rs/156898-transfer-case-actuator.html

Whatever you do, don't try to remove the actuator without taking the transfer case apart. The timing will never be the same.

More good info (see post #12):

http://www.toyota-4runner.org/4th-gen-t4rs/135727-installing-used-transfer-case-actuator-motor.html

 

[Volley]

Thank you, great info! Looks like she's going with a replacement T-case. About the same cost/work than just the actuator and since she's over 200k miles can't hurt to have one in there with a bit less wear I guess. I just hope her shop is credible...

 

[paraordnance]

Got mine unstuck by undoing the bolts on the actuator enough to give me some play, (1-2 mm only!!!) and then GENTLY tapped it with a rubber mallet while someone in the cab toggled the switch back and forth in neutral.

Gummed up actuators are pretty common, but being stuck in 4 lo would suck. Hope you get it.

From what little I know about this, there is a way to get the actuator unstuck once you go through all the trouble of getting it apart:

http://www.toyota-4runner.org/4th-gen-t4rs/182074-fixing-transfer-case-shift-motor-leak-within.html

Or without removing the actuator from the t-fer case (have no idea if this worked, but he is super careful and it seems legit. I personally wouldn't try it):

http://www.toyota-4runner.org/4th-gen-t4rs/156898-transfer-case-actuator.html

Whatever you do, don't try to remove the actuator without taking the transfer case apart. The timing will never be the same.

More good info (see post #12):

http://www.toyota-4runner.org/4th-gen-t4rs/135727-installing-used-transfer-case-actuator-motor.html

I can confirm that mentioned above is definitely works! I had my actuator stuck in 4Lo two days ago and dealer quoted me $1900 for the part and 13 hours for labor! Ouch.. I crawled under truck, loosen up 3 bolts, pried out actuator assembly away from the TC with large screwdriver (max couple mm!) and had my wife switch to 4Hi while I was slightly hammering on actuator with rubber mallet, on second attempt it switched!!! I can't see myself spending $3-4K on luxury of having a 4Lo again. Which I never used in a first place.

 

[Volley]

Thanks for the help all. New "used" tcase went in yesterday

 

[Slowgoat]

What's the damage on something like that?

Always wondered how much it cost out the door.

 

[Volley]

Was about 1600 950 for the tcase with lifetime guarantee and 650 labor

 

[paraordnance]

Its sad but true, much cheaper to replace the whole transfer case than deal with replacing actuator. I found new OEM transfer case for $2800 (Canada) used one can be found for around $1000.

 

[Volley]

Yep that's why I went the route I did. Mine is used but with the guarantee I figured it was worth it. Would have been 100 cheaper without the guarantee.