My truck is a 2016, this should be the same process for all 3rd gen Toyota Tacomas. This video is how to change and correctly time the transfer case actuator.
Also, notice how the vent hose is split a little on the end. This is the failure of a lot of these units. The hose splits over time and falls off, then water gets into the unit. This would be a good time to snip a little off the end of the hose before reinstalling. I've done this once on my truck as a preventive measure since it was split, but not to the point of failure. It looks like on the 3rd gens, they left the vent hose plenty long to accommodate this. Check your ADD actuator and rear diff locker for this as well, if your truck is equipped with them. Great video!
Thanks much for taking the time and effort to do this video! It is 10 degrees here now and I was stuck in low range. 2017 Tacoma standard. I searched quite awhile for info on resolving this issue. Your video is the only one that explains exactly what must be done. I down loaded the factory service manual and it was no help. I am 74 and well experienced in working on all sorts of mechanical devices, having worked professionally as a motorcycle mechanic for 15 years, still working on cars, trucks and tractors, and motorcycles! You definitely saved me on this cold day working in an unheated garage, snowing blowing outside. Feeding cattle a round bale earlier this morning on my cab less tractor was cold with the wind chill. It is quite amazing what can be found on the internet, done by people like you! thanks!
@@timst5055 Thanks for your video. My 2016 Hilux had same error after the front actuator was replaced. Now it doesn't show 2wd - 4wd error anymore, with no abs light on. Vehicle just still doing rapid 4Lo blink when trying to engage 4H. What else can I try? Removed and reinstalled 3 times today and made sure everything from shaft position to gear timing marks still the same.
@@Erick.___90 finally someone replying at least! I read that the rod must also be moved back and forth a lot to ensure it moves better again. I last had 4wd in June 2023, so will try and move the rod this week and see if that helps now. I noticed it was difficult to move when I opened the actuator cover. When last did your 4wd engage?
I wish I saw this video before I took my truck to the dealer. They want $1500 to fix it. Mine was stuck in 2wd. After they spent 5hrs diagnosing it, they said it’s now stuck in 4wd. I’m going to pick it up in a few min armed with tools and this video!
Was having similar issues with my 19 taco(6sp manual) with only 11K, as can be seen in a couple prior recent comments. Here is a CRAZY update which I have absolutely no explanation for. As I’ve mentioned,I removed , inspected, lubed and reinstalled the actuator. It worked a few times but went right back to either not going into 4l, or if it does it won’t come out. TRY THIS! FULLY DEPRESS AND RELEASE THE CLUTCH PEDAL 2 TIMES. As you are releasing the pedal the second time, it will click in(or out) I could not believe this when I was told by my local Toyota shop manager. He has no explanation and just found this out. I immediately thought BS, but happy I did not flip out on him . I tried it and it works perfectly every time going into and coming out of 4 low. Sorry I do not know what to tell the owners of automatics.
Very nice video my 2005 Tacoma was always a little touchy going into 4W LO and once I had a difficult time getting it out of that mode and almost had to park it and possibly have it towed I always tried to at least cycle the 4WD once a month to keep everything moving inside the actuators both on the transfer case and front differential but now all I have is 4W HI and there are times when I could use LO because my truck has the 2.7 4cyl and 5 speed not much in the Horsepower department lol
Great vid. Holding the parts upside down was much easier than I expected. I’ll pass on a tip. It’s possible to damage the seal when placing the actuator unit back on. Wrap Teflon tape over the gear notches on the rod that goes onto the transfer case. That will protect the seal as you slide the actuator assembly over the rod. Unwrap it after it’s in the assembly but be careful not to tear it and leave any on the rod. Thank you.
Well I’m in the stealership right now with the same problem. Only 16,000 on the truck so luckily still under warranty. I snuck back into the service bay to have a look and they had the entire transfer case on the floor. The service tech says it’s a bad actuator, but I can’t understand the need to drop the entire transfer case!!
To fit a completely new actuator (box and rod) the transfer case must be removed, which likely means the complete transmission. Then the transfer case must be partly dissembled to remover the various internal clips and positional ball/springs that hold the actuator rod inside the transfer case. You will find an Aisin RU-vid of the complete procedure, which clearly shows why they do it that way.
FUUUUUCK, I skipped to 1:17 and was watching super chill following along....Then all of a sudden you're taking the actuator off with both hands and pointing with your third hand .....trippy af.
Nice video, just one small correction though. The transfer case only switches between high and low, and the front diff switches 2wd and 4wd. So, basically putting the tcase back into high, which fixed it.
I wish this video had been made earlier lol! I replaced the actuator in my 2016 Tacoma the hard way! Had to drop the tcase, split it apart, and I put in a whole new actuator unit from aisin. It was such a pain and the failure happened so early in the trucks life that I got rid of it the day after I did the repair-my thought process was that nothing in such a new truck (2 years old at the time with 80k miles on it) should ever break so I figured it was a lemon.
Hey, thanks for the video. Random question. I have a 98 4runner limited with a button to engage 4wd. When changing the transfer case fluid, I noticed a metal ball detent at the bottom of the drain pan, which I assume is the shift linkage detent. The only difference after changing the fluid is engagement of 4wd is silent(assuming it's from fresh fluid), but everything seems to work as normal aside from that. Tested my luck lol. My question is, are there other mechanisms keeping the linkage in place that has allowed me to stay engaged in 4wd without that shifter detent? I'm wondering how much work those detents actually do to keep the linkages in place once in 4wd. Any insight would be greatly appreciated. Thanks a ton.
That was very well done. Wondering how close it would be to a 2005 Sequoia that I have with the same problem - but I'm stuck in 4High -- Dealer wants to Replace entire Transfer case for $4000 Dollars.
Thank You for this Tim. Been having this same issue with my 19 sport (3 pedal) with only 11k. The Toyota procedure for replacing the actuator involves removing and splitting the case. Why? Absolutely no reason I can see. Everything inside the case gets plenty of lubricant and the “sticking” issue is not inside that I can see . Though You fixed the immediate problem, I would like to figure out “what” is causing it? I’ve seen some that actually have to bump the shift shaft in with a hammer(rubber mallet) to get it freed up. So I’m thinking gob a generous amount of maybe some of that white lithium type grease in the area where it goes through the case from the actuator side . Gonna give it a try today and see what happens. Nothing to lose. And thanks again.
@@timst5055 Well, it was worth a try, but is definitely not a lubrication issue. Where the shaft passes through the housing, there is actually a notch that allows for oiling and is sealed on the outer side. I could not see that in the video but was very apparent when I got into it. I lubed up all the plastic liberally with white lithium grease, put it all back together and it worked great, for about 6-8 cycles. Then it returned to the same problem. It either won’t go in to 4L, or it goes in and won’t come out. So I’m calling it a Toyota actuator problem that they need to address. It takes a good bit of energy to move that selector shaft and I don’t think the plastic components and possibly the motor are up to the task. Toyota needs to step up on this issue. Thank You! 👍👍🇺🇸
Great video, im currently on deployment and before i left, i tried this with a new actuator because the other one broke. I installed it and it switched from 2wd to 4hi and 4lo with no issues but when i tried going back to 4hi and2wd it wouldnt go. It just stayed in 4lo, do you think i got the timing wrong?
I'm curious, where did you learn the information regarding the correct timing for the gears? Do you have a source to share? I looked up factory service manual information from the Toyota Tech Info website and did see anything about taking apart the actuator.
I looked through every manual, asked multiple Toyota dealerships, tried looking online and couldn’t find anything. Then came the trial and errors. Eventually, I purchased a new one and carefully took it apart and saw how it was positioned at the factory. Put it in the same way and it works.
@@timst5055 I appreciate you getting back to me. I applaud your dedication to getting the answer you were looking for. I might be helping a guy figure out an actuator issue on his Lexus GX470 soon and your video will be listed as a reference if I make a video of the job. Thanks!
Hey Tim we attempted this this afternoon with no luck might not have had one of the gears in the correct way possibly is their any trick to making sure the rod aligns with the cog easily? Cheers
Hey Ryan, I think the easiest way is to slide in the biggest gear first to line it up, then have someone help hold it in place. Hopefully you’ll get it the next time you try! Thanks!
Make sure the rod is fully pushed into the transfer case. If it’s not, the gear marks won’t really be in the right position. In this video, his wasn’t fully seated, if it was, the alignment marks would have been closer. Fortunately, he errored in the right place. If he’d errored to the other side, it probably would have intermittent issues on his switch’s.
@@Papparratzi any way you can clarify "the alignment marks would have been closer"? which part in this video just trying to see if this is something I can reasonably handle but don't want to screw up on such an expensive part ;)
Either your actuator is bad or your actuator skipped timing. Try following my video and resetting the timing before buying a new actuator. If that doesn’t help you might need a new actuator.
Hi Tim. I have a 2nd gen Tacoma. I know my actuator is different from the 3rd gen. What I’m asking do you know if I can use the same procedure to push the actuator rod back into the transfer case on a 2nd gen.
Hey Robert, maybe try taking off your actuator and seeing if you could push the rod back in. I’d assume it’s the same type of technology. Let me know how it goes, good luck!
@@timst5055 I did some digging and found out the position of 2 wheel drive, 4 wheel drive and 4 high position in the actuator. I found out my actuator motor is broken. I wish that Toyota sells just the little motor. I took the black cover off with the motor. I then hand turn the gear all the way to the left until it can’t go no more. That’s the 2 wheel drive position. The 2nd gen Tacoma transfer case system is different. You cannot push the actuator pin in as you do with the 3rd gen. I heard that the 1st gen taco you tap the pin back in. I don’t need 4 wheel drive anymore. I don’t live in the northeast anymore. Thanks Tim.
@@robertchen9686 that’s great to hear. I remember reading on some forums that the solder connections on the motor sometimes fall apart, maybe all you need is to solder them back on and the motor might work again. Anyway, thanks for finding out the second gen info though, might help some other second gen owners.
Always check if the breather line is properly attached to the actuator. If not water get inside and corrode the contacts....giving solid or intermittent problems.
what type of issues would this cause? i checked my breather tube and noticed it had split and was coming undone so i snipped that piece off and pressed it back on
@@chrislee4946 The front actuator was replaced on my Taco 3 weeks ago. Working good now. It was a warranty job by Toyota dealership so I couldn't get the part to inspect myself. It's very important to regularly activate the 4L and 4H. Its even recommended in the owner manual.
I have a problem with my 2020 Tacoma TRD off road The rear locker will not engage.the part number is 84222-0K010 switch transfer indicator. That part was damaged. I removed the damaged one and installed the new one. The rear locker will not engage. I need help please
Did you get help? My error cleared today, but when switching to 4H, the 4Lo light blinking and peeps rapidly. 2016 Hilux. I wonder what could cause the trouble now, previously showed 2wd - 4wd malfunction, but that gone now and thought my problems is over. 🙃🙃🙃
I’m not sure if it’s the same process. Maybe try taking it apart, it might be the same or only a little different. Swapping it out yourself would save you $3600, so I’d give it a try.
The actuator assembly. You could try taking apart your old one and trying to see if it just skipped time. You might be able to save your old one and not have to buy a new one, just time it correctly and test it out.
Thanks for this. It worked and got me out of 4LO, but as soon as I tried using 4LO again it got stuck again! Does this mean that the actuator is bad? Anyone else experiencing this?
I just opened the actuator on my 2008 4Runner, the 2 big gears fell off and can't figure out how to put back in. I randomly put the gear back and now the 4WD lights is always ON blinking no matter how I turn the selector switch. This video will definitely help me with the timing. Will open the actuator again tomorrow. Thanks a lot.
Hi Tim yes, great video. I am having a problem with 4 lo selection the transfer case goes to 4 lo but the Lo light is still flashing on the dash, and I get a beeping once I select drive! Do you have any clues to my issue? Thanks, Mark
@@Lokalboie24 oh yeah, replaced the unit! The original had a major crack, sucked water! It took a bit of fiddling to get the new unit in but worked all good once I got the timing correct.
dang 40k and already a problem. i have a 2010 and sometimes from 4WD back to 2WD it will just stay blinking. i will start to drive slow with light blinking and will cluck back in. might just go to dealer this year and get it done.
I didn’t use the 4x4 for a while and then one time I did and it got stuck. It’s recommended to use it once a while and also to follow the instructions how to switch in and out of the modes. Driving slowly forwards or backwards helps the gears engage, so if It ever blinks try going forwards or backwards a little. Hope this helps
@Tim St yea all gears ⚙️ are line up. First time I can't get into 4 low. Now I can't even drive if it's on 4 high. Solid green light but can't drive, but I am able to put in 2wd easily... then it drives. Will do it again tomorrow..
This video is great but still doesn't explain why this happens and nothing was done to prevent it from happening again. Any ideas why this happens? Why is it getting stuck?
Not sure exactly why it gets stuck, but earlier to this I didn’t use my 4x4 at all and then one time I turned it on. After that it wouldn’t come out. Could’ve been a case of use it or lose it. I made it a habit to cruise around in 4x4 every once in a while. Hope this helps
The owner's manual recommends driving 10 miles/month in 4WD in order to keep the system working correctly. Not using the 4WD regularly can cause the actuators to stick or malfunction, this is the most common reason for problems with the 4WD system. Besides the actuator on the transfer case, there is one on the front differential that disconnects the front axles so the differential and drive shaft won't spin while in 2WD (saving gas and wear and tear). Exercising the 4WD will keep both of these actuators moving freely, the more often you use them the quicker they shift. Same thing with the rear locker, if you have one, engage it once or twice a month and it will work much better when you need it.
I was wondering the same thing. “What” is sticking or malfunctioning? Thought perhaps it might be where the shaft goes through the case and perhaps lubing it very well with some lithium grease may help? Gonna give it a try. My truck is a 19 sport with only 11k and has had this issue since I got it new. C’mon Toyota!
Question is this the same setup as say an 04 Toyota 4runner 4.7l v8. Cause i think my wifes was failing for a long time it sucked in snow then it could only move in 4 low. Then i tried to move it to my project pile but it wouldn't move at all says its in 4low with diff lock on but won't move at all and sometimes grinds id you try to put it in gear. I had this cover off the transfer case actuator but i had no red gear just those other three gears. I tried to take them off and remove the actuator but it wouldn't budge even gently with a pry bar.
I have second gen tundra and I’m buying a new transfer case, but it doesn’t come with the shift motor. Can that rod be pulled out and put in the new transfer case without taking the whole unit apart?
I have second gen tundra and I’m buying a new transfer case, but it doesn’t come with the shift motor. Can that rod be pulled out and put in the new transfer case without taking the whole unit apart?
