Solution too 4wd "not engaging" my symptoms and solution

[MR.H]

Update for 4wd not engaging, w/ write up and lots of pics.

So its been a year now and putting all the information together to solve this has been daunting for me. Albeit speradic.

Base Info:
1996 SR5 5spd

Symptoms:
When shifting into H4 nothing happened, no lights indicated, no flashing lights, no vacuum supplied to t-case. Same for L4.


Troubleshooting:
Was able to switch vacuum lines at the VSV (vacuum switch valve) in the engine bay on driver fender. Then that supplied the necessary vacuum to engage H4 or L4

VSV shown here. I flipped the two hoses and marked one to keep in mind that it was supposed to be on the right side.

Also, I pulled the cover off the gear stick lever to spot the transfer case and transmission. Found two switches on either side of the t-case, un-plugged one and shorted the switch, shifted into H4 and all worked. Measure the resistance of the switch and found a faulty reading. Checked the other side and same thing (faulty reading).

To get to it, first pop the e-brake cover off.

Then the shifter cover.

One of the switches to test. Make sure to test the male side. The female side is where I used a small wire to short, which resulted in restoring the vacuum.

Here is how I tested it, this can be done in the car and shifting the J shifter into different positions to check, or out the car manually pushing in the switch.

Put either probe on either contact, you are measuring resistance so positive and negative are irrelevant.

This photo shows the switch open, with a reading of Overload.

This photo shows it closed, giving me a reading of ~5ohms. The closer to 0 the better, this is a used sensor and is better than the readings I have gotten in the bad ones, so I used them! If you get a reading over this and into the teens, that says the sensor is bad.

Solution:
Transfer Indicator Switches need to be replaced (although maybe a cleaning would do it)


Located here top side, looking from under the car. Notice Opening to the shifter and cabin.

And another view from the top looking down.

Then I stuck a 10" adjustable wrench in there to remove it. All you need to do is essentially "crack" it and the rest of the turning can be done by hand, these arent very tight, and dont need to go on tight either.

Then the reverse im sure you can figure it out to put it all back together. If you have any suggestions or questions, please dont hesitate to post!

And a big big thanks to Deathcougar, for his continued support in my questions about how to fix this. Everything is working perfect, and cant wait to use it to its fullest extent.

Part Numbers:

84222: 84222-35110 SWITCH, TRANSFER INDICATOR, NO.1. SWITCH, TRANSFER INDICATOR, NO.1 (11.1995-08.2000) RZN185,VZN185..SR5B,SR5V;

84222B: 84222-35080 SWITCH, TRANSFER INDICATOR, NO.2. SWITCH, TRANSFER INDICATOR, NO.2 (11.1995-08.2002) RZN185,VZN185;

84222C: 84222-35070 SWITCH, TRANSFER INDICATOR, NO.3. SWITCH, TRANSFER INDICATOR, NO.3 (11.1995-08.2000) RZN185,VZN185;


Hope this helps. I will add pictures later today.

 

[Grenvilleter]

Pics would be cool. Lots of folks are always asking.
Failure is common to these switches it seems to new owners myself being one of them.
Perhaps failure is too strong a word and as you say, a good cleaning would help.
May be it's more prevalent in rigs where 4x4 was not "exercised" regularly because once it's working seems nobody that has a working system sees failure ?

Are they N.O. or N.C. switches ?
What each switch controls would be nice if you figure it out.

I had a failed system as mentioned and through swapping over parts from my parts truck, I was able to get the system where everything worked except when I commanded it to go out of 4x4, it would not until I removed the power by shutting the truck off. I could live with that for the time being.
Had to swap out the tranny last fall so the donor truck came to the rescue again and supplied the tranny/xfer case.

Now...unit shifts in and OUT of 4x4 normally with instrument panel indication however now, no indicator on the dash when the xfer case is in neutral. Everything else seems normal.

Again, I'm not going to get my knickers in a twist because a neutral indicator light fails but wanted to say thanks for your effort.

I may be opening up my shifter soon and if I can change out the xfer case sensor at the same time, I will.

 

[MR.H]

Pictures up as requested, ill save a sob story for later and say I forgot, oh well.

I think they are N.O. switches. I had to short them for them to work, which I guess would be the indicator.

Any who, I can't seem to figure out which is which either.
TOYOTA 4RUNNER [VZN185L-GKMGKA] (USA) 11.1995-08.2000: ELECTRICAL GROUP: SWITCH & RELAY

This doesnt give a good representation on where either one is, and thats all I have been able to find.

 

[MR.H]

Bump? Can i do that?