Replace 2007 4WD shift actuator motor without removing transfer case?

[scottwangen]

I have a 2007 4Runner SportEdition V6 with blinking 4WD and Diff lights when I try to go into 4WD.

Is it possible to replace the shift actuator motor without removing the transfer case? Any DIY manuals/videos on how to remove old and install new? Mechanic quoted me $4000 to remove and disassemble the TC, install new motor, and reassemble/install.

I've seen this posting that suggests to me it can be done, but requires disassembling the motor. Is that correct?

Appreciate any help. Thanks in advance!

Thanks,
Scott

 

[hearno]

A few threads on this issue if you search for them. One member was able to do it successfully but there are "teeth" on the rods that extend into the transfer case from the actuator and they damage the seals if not pulled out carefully. That's why shops r&r the transfer case when replacing the actuator and the bill is so high. There was a method detailed by the guy that did it successfully. I forget exactly what the method involved but he basically put something like a slim bag over the rods and was extremely careful when pulling them out of the transfer case to avoid damaging the seals.

 

[ebg18t]

Not the easiest to do. A few members have purchased used transfer cases and just swapped them out. I think the dealer charges about $2500.

 

[BlackWorksInc]

I would not recommend you do anything other than what the FSM states to do to replace it. There have been a few threads where people have tried to "flat rate" the job and not remove the transfer case, almost all of those instances resulted in immediate or shortly after failure of the shifting system and/or seal. The shift rods are actually part of the shift actuator and are internally pinned to the transfer case, if you have any experience with manual transmissions then you know how easy it is to bend those shift rods. Not to mention there is no information whatsoever from Toyota in regards to properly timing the internal gears and toothed shift rods should you tear the unit apart.

There was one member who did tear apart his actuator and managed to put it all together, but he still said he needed to work on the gear timing because it didn't shift properly; that was the last I heard of that vehicle's repair. Not that his method wouldn't work or is bad, but it is highly technical and I wouldn't recommend it as a "this is my first time doing this" repair when you only have 1 transfer case, not to mention trying to trust a shop to do an essentially non-by the book repair.

 

[scw1991]

Are you unable to go from 2HI to 4HI? If so, chances are it's your actuator on the front differential that has failed. There are a few threads on the forum discussing this.

I just replaced mine and that solved the problem....almost. It would shift from 2HI to 4HI but not 4HI to 4LO. I slightly loosened the 3 bolts that mount transfer case actuator and gave it a jiggle. Tightened the bolts back up and it shifted from 4HI to 4LO with ease. The transfer case actuator that also engages locking center differential also worked as intended.

From what I've read on the forum, these shift rods get gummed up from lack of use.

 

[mallard]

I am having the same problem with my 2007. It will shift from 2hi to 4 hi but not 4 low ( just blinks). Are you saying the fix is to loosen the bolts? Then re-tighten?

 

[Az4runnin]

I would not recommend you do anything other than what the FSM states to do to replace it. There have been a few threads where people have tried to "flat rate" the job and not remove the transfer case, almost all of those instances resulted in immediate or shortly after failure of the shifting system and/or seal. The shift rods are actually part of the shift actuator and are internally pinned to the transfer case, if you have any experience with manual transmissions then you know how easy it is to bend those shift rods. Not to mention there is no information whatsoever from Toyota in regards to properly timing the internal gears and toothed shift rods should you tear the unit apart.

Absolutely! Get it done Right the 1st time. Not worth the expense if done incorrectly and Cost way more. Ya it sucks that it's Not a simple 2 minute job but Not worth F'ing it up. Man I'm Lucky my Buddy is a Toyota Tech and is going to do this for me. I am going to have him try to document with pics if possible. Mine shifts into 4lo and Center Lock works Ok just seal is bad. Just keep in mind toping off and checking fluid level often.

 

[scw1991]

mallard,

First I shifted from 2HI to 4HI in my 07' T4R (51,000 miles on odometer)

Second, I confirmed that both actuator motors were operational at the transfer case. One actuator motor is to engage 4HI to 4LO. The other actuator motor is to engage the Center Differential Lock. Neither of the actuator motors would engage at the transfer case.

While still in 4HI, I engaged emergency brake, shifted to neutral, and switched from 4HI to 4LO. I got underneath car and could hear the 4HI to 4LO motor trying to engage. There was also a faint beeping sound coming from the actuator. That was a good sign.

I turned engine off. I used a 12mm socket/ratchet and wrench and slightly loosened the Qty-3 bolts that mount actuator assembly to transfer case. I gave it a few wiggles and tightened up the bolts.

Got back in the car, started it up and bingo! 4HI to 4LO actuator engaged. I pushed center differential lock button on dash and this actuator engaged as well.

 

[chmura]

Absolutely! Get it done Right the 1st time. Not worth the expense if done incorrectly and Cost way more. Ya it sucks that it's Not a simple 2 minute job but Not worth F'ing it up. Man I'm Lucky my Buddy is a Toyota Tech and is going to do this for me. I am going to have him try to document with pics if possible. Mine shifts into 4lo and Center Lock works Ok just seal is bad. Just keep in mind toping off and checking fluid level often.

That would be awesome.

Someone needs to document this repair with pics! I feel more comfortable splitting my t case than purchasing a used one with an unknown history.

It's been 11+ years since the 4th gen 4runner has been out already I'm surprised that a proper DIY has not been done by anyone!

 

[mallard]

mallard,

First I shifted from 2HI to 4HI in my 07' T4R (51,000 miles on odometer)

Second, I confirmed that both actuator motors were operational at the transfer case. One actuator motor is to engage 4HI to 4LO. The other actuator motor is to engage the Center Differential Lock. Neither of the actuator motors would engage at the transfer case.

While still in 4HI, I engaged emergency brake, shifted to neutral, and switched from 4HI to 4LO. I got underneath car and could hear the 4HI to 4LO motor trying to engage. There was also a faint beeping sound coming from the actuator. That was a good sign.

I turned engine off. I used a 12mm socket/ratchet and wrench and slightly loosened the Qty-3 bolts that mount actuator assembly to transfer case. I gave it a few wiggles and tightened up the bolts.

Got back in the car, started it up and bingo! 4HI to 4LO actuator engaged. I pushed center differential lock button on dash and this actuator engaged as well.

This is really similar to my issue. 07 t4r at around 60,000 miles. It was my wife's truck prior to me having it so 4x4 was never used. 4hi works and just blinks on 4low. Found this out trying to traverse a rock slide on the side of mount Princeton... It was a pucker fest. I guess I did not realize there were two motors. Do you happen to have a picture of it? I was down there lubing the propeller shaft and think I saw it on the back side of the t-case. I had a situation with a GM product where the stealership tried to charge $2,500 to replace an actuator but I bought a used one on eBay and three bolts later felt pretty good about myself. This seems a little more complicated.

The Toyota stealership said $2,500 to $3,500 for the repair and warned me not to shift into 4 hi that basically the actuator was going out and could get stuck. Just didn't seem right to me.

Thanks for the help

 

[scw1991]

Here is the thread with pics of actuator assembly disassembled.

http://www.toyota-4runner.org/4th-gen-t4rs/80283-2004-v8-4x4-actuator-replacement.html

 

[NasaE30]

Had the same problem. I just swapped the transfer case.I found a used one locally 50k miles with a 2 year warranty $400. Just swap it. Get a new output seal while your in there. Search my thread on this and you will find the oem part number. You will have a leak if you damage the old one.

 

[mallard]

Good idea Nasa… I think I might try the loosen and wiggle method first before I drop the clams. The actuator motor alone is more than $400 bucks from what I can find.

 

[NasaE30]

Check Car-Part.com--Used Auto Parts Market. that's how I found mine

 

[crazyborder]

Did anyone have any luck with the loosen, wiggle and tighten? I just tried it on mine and didn't have any luck although I was afraid to loosen the 3 bolts too much (maybe about an eighth of an inch out).

If you did try it, how loose was the actuator housing and how far out did you loosen the three bolts? Mine would barely move without some gentle persuasion (runner mallet). I did notice that the top of the housing barely moved at all and was very tight against the transfer case and would pull back immediately if I tried to gently pry it away from the case. Again, not sure if this is right or if mine is just severely locked up. Any feedback would be appreciated!

 

[Slowgoat]

Did anyone have any luck with the loosen, wiggle and tighten? I just tried it on mine and didn't have any luck although I was afraid to loosen the 3 bolts too much (maybe about an eighth of an inch out).

If you did try it, how loose was the actuator housing and how far out did you loosen the three bolts? Mine would barely move without some gentle persuasion (runner mallet). I did notice that the top of the housing barely moved at all and was very tight against the transfer case and would pull back immediately if I tried to gently pry it away from the case. Again, not sure if this is right or if mine is just severely locked up. Any feedback would be appreciated!

I did. Did you ever get it working? Did the 1/8", loosening the bolts, got a buddy to shift back and forth for me into and out of 4lo, while tapping it with the rubber mallet, and it started working.