Transfer case issues? Try these factory inspection steps

[Monkey Wrench]

My transfer case wouldn't go into 4lo when I first bought the truck. It would go into 4hi and the center diff lock worked, but I tried everything with no luck to get the truck into 4lo. Tried every possible combo of shifting- 2hi straight to 4lo, 2hi->4hi->4lo, etc and tried rolling forward, reverse, slow, fast... nothing worked.

Took it back to the Toyota dealer and these are the steps the did to fix it for free. Basically they were going through the inspection steps and 4lo started working. Maybe it was a coincidence, or maybe unplugging and plugging wiring harnesses did something. Either way it saved me lots of time and money.

Hope this helps, not my fault if your 4Runner blows up.

 

[Monkey Wrench]

...the tech left this guide and 2 pieces of paper clip in the 4Runner . I don't think this took any special tools other than a multi meter and short pieces of metal/wire to jump connections.

 

[Schmuly]

Thanks looks like some good reading.

 

[Monkey Wrench]

At least it should rule out a lot of other components before diving into the transfer case right away.

 

[TowMeOut]

BlackWorksInc posted a Toyota training guide with very similar info. However, the stuff you have is more of a checklist. I think it's more useful as a "step by step" for those of us that don't tear into the 4wd system every day.

http://www.toyota-4runner.org/4th-gen-t4rs/147174-2003-4runner-4wd-problems.html

There are a good dozen different threads with a variety of posts about Tcase leaks, being stuck in 4Lo, ending up in neutral, or generally just not shifting at all. The 4th gen tcase is definitely the weak link in an otherwise awesome vehicle. I'm really surprised with the number of vehicles on the road that someone hasn't come up with a dual stick setup. Almost every problem is a result of the actuator and/or related electrical gremlins.

 

[Monkey Wrench]

I agree, it's surprising that there isn't a fully manual 4x4 set up for these 4Runners yet. Didn't inchworm or marlin crawler make something in the past? I did some research when I thought I was going to have to repair/replace the transfer case, but couldn't find anything.

 

[BlackWorksInc]

I agree, it's surprising that there isn't a fully manual 4x4 set up for these 4Runners yet. Didn't inchworm or marlin crawler make something in the past? I did some research when I thought I was going to have to repair/replace the transfer case, but couldn't find anything.

Well it'd have to be an all-time 4WD unit with no CDL to be completely manual and not need custom axle hubs.

 

[Monkey Wrench]

could you set it up all manual, and use a CDL button? If so, how?

 

[Monkey Wrench]

could you set it up all manual, and use a CDL button? If so, how?