Transfer case replacement issues

[TNFISHRMAN]

Guys I need a little help. I have a 2004 V-8 4runner AWD and recently lost a transfer case (No oil in the old case was the issue. I must have bought it like that because I did not have any oil in the driveway or underneath the vehicle that had leaked) and had to replace with a good used unit from a company called LKQ. I installed the new to me used transfer case and tried the unit while it is on the Jack stands. I am only getting output from the rear of the Transfer Case. Left rear wheel is the only thing turning. I tried switching from 4hi to 4 low and still nothing. I did notice I had a VSC off and VSC Trac light on. I tried differential lock button. Still nothing. I can hear the Actuator working when I try to switch from 4hi to 4lo or from 4lo to 4hi but do not have any movement from the front output shaft of the Transfer Case. Can anybody get me pointed in the right direction as to what might be the problem?

 

[rdruss]

You have apparently asked the $64 question!
I have an '03 V8, AWD but have never tried it with all 4 wheels in the air, I did however try it with my '07 AWD Highlander and it was a bit un-nerving as all the brakes started to cycle on/off as if vehicle was on ice and it was trying to find traction and it almost jumped off the jack stands so I shut it off.
I guess I would expect same from 4Runner.
Only thing I can think of is if there is something wrong with the chain drive from main/ rear output shaft to the shaft that drives front.

I'm not expert on this drive system.

Hope somebody with more knowledge chimes in!

 

[AuSeeker]

Guys I need a little help. I have a 2004 V-8 4runner AWD and recently lost a transfer case (No oil in the old case was the issue. I must have bought it like that because I did not have any oil in the driveway or underneath the vehicle that had leaked) and had to replace with a good used unit from a company called LKQ. I installed the new to me used transfer case and tried the unit while it is on the Jack stands. I am only getting output from the rear of the Transfer Case. Left rear wheel is the only thing turning. I tried switching from 4hi to 4 low and still nothing. I did notice I had a VSC off and VSC Trac light on. I tried differential lock button. Still nothing. I can hear the Actuator working when I try to switch from 4hi to 4lo or from 4lo to 4hi but do not have any movement from the front output shaft of the Transfer Case. Can anybody get me pointed in the right direction as to what might be the problem?

You have apparently asked the $64 question!
I have an '03 V8, AWD but have never tried it with all 4 wheels in the air, I did however try it with my '07 AWD Highlander and it was a bit un-nerving as all the brakes started to cycle on/off as if vehicle was on ice and it was trying to find traction and it almost jumped off the jack stands so I shut it off.
I guess I would expect same from 4Runner.
Only thing I can think of is if there is something wrong with the chain drive from main/ rear output shaft to the shaft that drives front.

I'm not expert on this drive system.

Hope somebody with more knowledge chimes in!

As rdruss point out it could be an issue with none of the wheels having traction, have you tried it when the vehicle is on the ground and driving, if there's something still wrong it should be obvious at that point?

 

[TNFISHRMAN]

Thanks for the replies I was losing hope for some help. I have not tried it on the Ground and not on the Jack Stand. I am suspecting a bad Transfer Case from LKQ. But I will try to get it off the Jack Stands and try it tomorrow. I have been working 14 out of 15 days on 12 hour shifts. I really appreciate the replies!!

 

[rdruss]

Thanks for the replies I was losing hope for some help. I have not tried it on the Ground and not on the Jack Stand. I am suspecting a bad Transfer Case from LKQ. But I will try to get it off the Jack Stands and try it tomorrow. I have been working 14 out of 15 days on 12 hour shifts. I really appreciate the replies!!

When you get a chance, watch weberauto-youtube discussion of center differential transfer case. It is 41 minutes long but very good and he is discussing YOUR transfer case out of an '04 4Runner. He doesn't say that until he gets to the part about center diff, about half way through. You will see from watching this that there are a couple of areas that a rebuilder might not get it quite right; 3-cone clutch, put rear shift collar in backwards(if possible).
But I would definitely call rebuilder and tell him you situation.

 

[Fern]

These center diffs have no chains. They are gear driven like an open diff so without it being on the ground only one wheel will spin.

 

[TNFISHRMAN]

These center diffs have no chains. They are gear driven like an open diff so without it being on the ground only one wheel will spin.

Thanks for clearing that up. I still haven't gotten it back on the ground. I have had some other issues that need attention too.

 

[rdruss]

These center diffs have no chains. They are gear driven like an open diff so without it being on the ground only one wheel will spin.

Correct, CD has no chain, but the power transfer to the front drive shaft is via chain. And after watching video from WeberAuto, that is probably not the problem unless rebuilder left it out completely.

 

[_chassis_]

Have you done a road test yet?

If not, while the vehicle is in the air and in drive with 4WD selected, apply the parking brake gradually and notice any change in rotation of any of the four wheels.

 

[RonJR]

As stated, with 3 open diffs (center, front, rear), any combination of wheels turning while all are in the air is possible. 1, 2, 3, or all 4. Just depends on the relative drag of the various wheels, and the difference doesn't have to be much, because open diffs are very efficient at sending power to the lowest drag component.

Best way to check this out is grab a helper. With the vehicle on stands, turn off the engine, and put it in park. Have the helper hold one front wheel stationary while you turn the other. The front drive shaft should turn, along with at least one rear wheel. If that happens, your tcase is just fine.

If you lock the center diff, it should not be possible to turn either drive shaft with the transmission in park. Turning one wheel on an axle should cause the other one to rotate in the opposite direction. If your helper holds one wheel on an axle, the other wheel should not turn until you overpower him/her.

 

[AuSeeker]

Correct, CD has no chain, but the power transfer to the front drive shaft is via chain. And after watching video from WeberAuto, that is probably not the problem unless rebuilder left it out completely.

The transfer case he has installed was not a rebuilt one, it is a used one he got from LKQ, which is an auto savage company.

Quote from his OP...

" .....I must have bought it like that because I did not have any oil in the driveway or underneath the vehicle that had leaked) and had to replace with a good used unit from a company called LKQ...."

 

[rdruss]

As stated, with 3 open diffs (center, front, rear), any combination of wheels turning while all are in the air is possible. 1, 2, 3, or all 4. Just depends on the relative drag of the various wheels, and the difference doesn't have to be much, because open diffs are very efficient at sending power to the lowest drag component.

Best way to check this out is grab a helper. With the vehicle on stands, turn off the engine, and put it in park. Have the helper hold one front wheel stationary while you turn the other. The front drive shaft should turn, along with at least one rear wheel. If that happens, your tcase is just fine.

If you lock the center diff, it should not be possible to turn either drive shaft with the transmission in park. Turning one wheel on an axle should cause the other one to rotate in the opposite direction. If your helper holds one wheel on an axle, the other wheel should not turn until you overpower him/her.

Thanks for this response I'm going to try this when I rotate my tires soon. However, I have a question about AWD, which is what I have as well as TNfisherman. When we go from park to drive on the gear selector does that also move the internal collar in the Tcase to engage the front drive shaft?

As I stated earlier I'm not an expert on this system but appreciate the weberauto video that explains how the tcase w/CD works … an example of mechanical wizardry in my estimation!

 

[TNFISHRMAN]

Thanks again guys for the replies. You have given me plenty to work with once I get up from my last 12hr graveyard for a while.

 

[RonJR]

However, I have a question about AWD, which is what I have as well as TNfisherman. When we go from park to drive on the gear selector does that also move the internal collar in the Tcase to engage the front drive shaft?

No. On the AWD (full time 4wd for the purists) V8 4Runner, the front drive shaft is always engaged. There is no movable collar or other mechanism in the transfer case to disengage it.

The multimode tcase in the V6 4runners has such a mechanism, but it does not ever move when the transmission is shifted; only when the tcase is switched from 2wd to 4wd.

 

[TNFISHRMAN]

Guys I wanted to give you all a quick update. It looks like I will be pulling out my transfer case again. I went to a Toyota technician friend and we worked with it for about an hour. We never could get the front end to engage and turn. When we tried the differential lock switch the actuator motor on the back of the transfer case would beep. He tried a few things he new but we never got the beeping to stop or the front to engage. So it looks like LKQ will be getting this one back to swap out. Hopefully with the next one I will have better luck. Thanks you all for the replies.