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Need help with my 4WD System

Discussion in '4th Gen 4Runners (2003-2009)' started by Muradsrt, Oct 28, 2020.

  1. Oct 28, 2020 at 2:20 PM
    #1
    Muradsrt

    Muradsrt [OP] New Member

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    Hey i have a 2003 Toyota 4Runner Full time AWD 4.7 v8 Sport.

    My Vsc trac, vsc off and the yellow centre locking diff light is blinking . I initially bought this vehicle with the light on. When i switch my 4wd switch into 4 LO there is no lights, sound or click.It does nothing. Also the Centre locking diff switch does nothing as well, there is no light that comes on or any sound from the relay. i have checked the 4wd fuse under the dash on the driver side, it was good. I pulled off both connections for both switches and found 0 power going to any of them. I also removed the plug on the actuator on the transfer case and found 0 power there too. I used a test light and touched the pins. Im a mechanic my self and am trying to diagnose this problem by my self. I know these trucks are notorious for having seized actuators but in my case i have no power going to anything. I have tried to reset the ecu by unplugging the battery and reconnecting and still got nothing. Would be great if someone can help me out.
     
  2. Oct 28, 2020 at 7:04 PM
    #2
    fajitas21

    fajitas21 New Member

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    Custom scratches
    Rats eat the wires between the fuses and actuators?

    I know the actuators like to get stuck but if you're not getting power then that's something different all together.
     
  3. Dec 24, 2020 at 8:50 PM
    #3
    Muradsrt

    Muradsrt [OP] New Member

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    Can anyone help? I just disassembled the centre diff lock and found nothing wrong . Gave power to the motor and it was spinning fine. Replaced the 4wd ecu with 2 other ecus and the problem is still there. where can i find the relay or fuse for this? Im going crazy
     
  4. Dec 25, 2020 at 9:06 PM
    #4
    Muradsrt

    Muradsrt [OP] New Member

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    I have checked both fuses IG1 and 4WD FUSE. Checked wires until 4wd ecu they both have power and work. Besides that no other wire in this diagram has power at all. I have replaced the 4wd ecu with 3 other used ones and still no luck. These ecus arent that easy to mess up either.

    image.jpg
    5163BCD7-2A65-4173-9C49-552CF8A7347B.jpg
     
  5. Feb 22, 2021 at 1:06 PM
    #5
    AlabamaGunWorks

    AlabamaGunWorks New Member

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    Any luck with this? I have the same issue on my 03 V8 limited. Thanks for any help
     
  6. Sep 26, 2021 at 5:38 PM
    #6
    JohnnyMac

    JohnnyMac New Member

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    I’d love to know how this worked out, I’ve had my 4runner since new and never had a problem other than the old stuck 4wd actuator problem, which I fixed by regularly switching it. Now however, when I switch from H4 to L4 and get no blinking lights and no actuator noise, I also have no power to any of the pins on my 4wd switch connector (other than 40mv on grn/silver and 10mv on wht/silver) and I’ve also checked the 4wd fuse and it’s fine and lastly I’ve disconnected/reconnected my battery and no luck. Any help would be much appreciated!
     
    Last edited: Sep 26, 2021
  7. Oct 17, 2021 at 6:46 AM
    #7
    kostya

    kostya New Member

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    Hi, two weeks ago just fix 4x4 on may 2008 v6. The problem was approx the same. The problem was in timing of t-case actuator. If you still need help, I can explain you all details.
     
  8. Oct 17, 2021 at 10:01 AM
    #8
    JohnnyMac

    JohnnyMac New Member

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    Yes Kostya! I would very much like to know how you fixed this! Thank you!
     
  9. Oct 17, 2021 at 4:08 PM
    #9
    kostya

    kostya New Member

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    The short story is:
    I bought 2008 v6 which stuck in 2wd mode. Dashboard lights track control and vsc off wore on and lights related to 4wd and dif lock wore blinking. The mode switch did not work as well as the diff lock button (no reaction from the actuator).
    In my case, the problem was with both actuators (v8 has only one).
    For proper functionality the ECU need working motors and proper feedback from encoders and sensor from actuator. My add actuator was stuck with open circuit and HI/LO encoder in t-case actuator was not functioned properly (the assembly mistake).

    Back to topic starter post, it is possible the ECU is not getting proper feedback from the encoder. It could be oxidation inside of the encoder or some connection problems. Probably the actuator was taken apart in the past and was not assemble back correctly.
     
  10. Oct 17, 2021 at 4:09 PM
    #10
    kostya

    kostya New Member

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    I started with front diff actuator and I fond it stuck in semi 4wd mode. It was it 4wd bun with out feedback from the internal sensor. After I fix that all light was off but shift to LO was not working. When I was trying to switch to LO mode LO on dash board was blinking all the time.


    So, I tuck apart T-case actuator and left only two rods inside on T-case. When I disassembled the actuator I checked mark on HI/LO encoder while T-case was in HI mode (the rod is all the way in)


    Wile the actuator was separated I checked the t-case. I manually moved the rod related to switching HI/LO. Then I checked both encoders and LO/HI motor. Every things was Ok.


    After I assembles the actuator by marks back the problem was still there (no shift to LO).


    The problem was in assembly of HI/LO portion of actuator.

    For proper functionality is not enough to pup the encode in the proper position. The spring mechanism on the gear should be a little charged. When I figured it out I assembled the actuator with different angle of encoder. When I turned the key firs, the encoder came to exact position for HI mode.

    After that I got LO mode back.
     
    Last edited: Oct 18, 2021
  11. Oct 18, 2021 at 10:13 AM
    #11
    kostya

    kostya New Member

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    On the schematic from post #4 you can see several groups of switches inside of the actuator.
    3, 4 and 5 this is the encoder and 9, 10 is the limit switch for 2wd/4wd/Diff lock portion of the actuator.
    11, 12 is encoder for HI/LO portion of the actuator.

    When the actuator is in 2wd and Hi mode (both rods are maximum in), the output should be:
    between 3, 5 and 6 – 0 Ohm
    between 4 and 3 – Infinity Ohm
    9-10 is open Infinity Ohm (do not sure about this one)

    between 11 and 10 - 0 Ohm
    between 12 and 10 - Infinity Ohm
     
    Last edited: Oct 18, 2021
  12. Jan 30, 2022 at 8:57 PM
    #12
    dlindf

    dlindf New Member

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    After searching through the forums I'm still having trouble timing the actuator.

    Does anyone have a picture of the lo-high and 2wd-lock-4wd dial positions for High range (rod all the way into the T case) and 2WD (rod all the way into the T case)?

    Do I need to do anything in particular when I change the timing, like disconnect the battery, clear codes etc or will the ECU change automaticaly by position?
     
  13. Feb 1, 2022 at 8:50 AM
    #13
    kostya

    kostya New Member

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    Hi, I will try to find my pictures. I successfully disassemble and assemble this actuator couple times.
    You do not need to do any manipulation with ECU. All magic is in those two “encoders”.
    In which condition the actuator now?
     
  14. Feb 1, 2022 at 11:52 AM
    #14
    dlindf

    dlindf New Member

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    I ended up gutting the lo-hi side and leaving it empty. I rotated the dials until the 4lo light went off. I then installed the 2-lock-4hi gears and coded.

    2hi-lock-4hi are all working now.

    I just can't figure out a way to get the actuator on the TC and set the gear timing on the lo-hi side becasue the 2wd-lock-4hi lever blocks me from putting the actuator case on.

    Got a suggestion from another forum user to cut a slot out in the middle tray so I can set the gear and dial timing on the lo-hi side, then slide the middle tray in over the 2-lock-4hi lever and proceed.
     
  15. Feb 1, 2022 at 11:55 AM
    #15
    dlindf

    dlindf New Member

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    Kostya, pics would be helpful to so I can get the spring charging right. Much appreciated!!
     
  16. Feb 1, 2022 at 3:22 PM
    #16
    kostya

    kostya New Member

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    First of all this is my references for this repair.

    1.
    Toyota Land Cruiser 150. Ленд Крузер 150. Ремонт Раздаточной коробки АКТУАТОР .Советую посмотреть .
    https://www.youtube.com/watch?v=FvmEfwXFJvY
    2.
    Снятие установка и разборка актуатора SURF 215/Sequoia
    https://www.youtube.com/watch?v=Kx3xkSSGw-Q
    3.
    Ремонт актуатора раздаточной коробки Surf 215 Multimode
    https://forums.drom.ru/4x4/t1152316915-p3.html
    4.
    DIY: Transfer Case Actuator Repair In video #1 the transmigration guy is showing the processes of installation of the actuator.
    In video #2 there is the process of installation as well
    #3 this is elaborate instruction about the actuator
    #4 another place with installation.
     
  17. Feb 1, 2022 at 3:59 PM
    #17
    kostya

    kostya New Member

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    Next I will use some pictures from those forums. I hope the authors of these pictures will not be mad on me )))

    Before the installation of actuator, both rods should be maximum “in” (lo/hi in hi and 2d/lock/4d in 2d).
    Set the encoder for lo/hi portion in position as on the picture 1:
    [​IMG]
    Then gently push the actuator toward transfer case. The rod will move the mechanism and the encoder will change the position approx as on the picture 2:
    [​IMG]

    After that, assemble the rest of the actuator.
    When you will turn the key to ON first time, the DC motor will move the gears and position of the encoder will move as it showing on pictures 1 (in this moment spring mechanism will be charge a little).
    This is it about lo/hi portion of the actuator.
    I did not add any modification for the actuator.
    I hope this information will help you to fix the actuator. At least it was working in my case.
    If you have any questions, fill free to ask.
     
    Last edited: Feb 1, 2022
  18. Feb 2, 2022 at 10:48 AM
    #18
    kostya

    kostya New Member

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    And one thing I forgot to add:
    Before the installation of the actuator on transfer case, you need to position the “half” gear as it showing on the picture
    [​IMG]
    The flat cutout should be touching the plastic housing. This is important. When you will start push it toward the transfer case, the rod will engage with this gear and gear will appear in proper position.
     
  19. Feb 16, 2023 at 8:31 AM
    #19
    4 running me crazy

    4 running me crazy New Member

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    Hi Kostya,

    Great post. Did you pull the pin that disengages the motor gear from the rest of the gears in order to pull the actuator off the TC?
    I pulled the whole TC, and got the actuator apart this way, and kicking myself in the arse.
    I have the same issue, I figured how to time it all but the 4w LO will not work the actuator motor because of bad timing I assume, so I need some help.
    Can you text me at +1 513-401-3646
    Once I figure all this out , I plan on posting all that I learned so that we can finally put these issues in one post.
     
  20. Mar 10, 2023 at 6:32 PM
    #20
    4 running me crazy

    4 running me crazy New Member

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  21. Mar 10, 2023 at 6:34 PM
    #21
    4 running me crazy

    4 running me crazy New Member

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    If you pull the right lower pin out, it, disengage is the gear behind it, allowing you to pull the whole actuator off the transfer case. It disengage is the gear from the motor that holds the actuator in place. Once the gear is removed well sorry once the rod is removed, the gear slides over and you can pull the actuator off but make sure that your marks are March before you do that and that when you push it back on and placed a pin back in at the marks lineup if the timing is corrected.
     
  22. Mar 10, 2023 at 6:39 PM
    #22
    kostya

    kostya New Member

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    Hi, yes, I pulled the pin before I pull the actuator from TC.
     
  23. Mar 10, 2023 at 6:42 PM
    #23
    4 running me crazy

    4 running me crazy New Member

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    I wish I would’ve learned that before I pulled a transfer case. No anyway have you been able to figure out how to set the timing for the low gear. Furthermore, I found that it’s possible that the front actuator might be causing a problem with the four wheel low.
     
  24. Mar 10, 2023 at 6:48 PM
    #24
    4 running me crazy

    4 running me crazy New Member

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    Would you mind giving me a call? 513-401-3646.
     
  25. Mar 11, 2023 at 4:18 AM
    #25
    Libagui

    Libagui New Member

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    I couldn't do it without this document.
     

    Attached Files:

  26. Mar 11, 2023 at 6:20 AM
    #26
    kostya

    kostya New Member

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    Hi,
    I added the file, in which, by memory, I explained how I made timing for LO\HI and 2H\4H of the of the actuator. It was done two times (first time I damaged seals an was need to replace them) without taken the TC from the car.
     

    Attached Files:

    Last edited: Mar 13, 2023

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