Topic: 07 tundra transfer case rebuild???

[SPLfiend]

Hey guys,

 I recently found out that the actuator inside my transfer case in my 07 tundra is sticking. Unfortunately, i have to remove the whole thing and crack it open to replace it. I have been told that while in there i might want to replace a few other things to save me future troubles. However, i have also read that these transfer cases are pretty damn reliable. I am not a rock crawler, i mostly use 4 wheel for when im out hunting and the primitive roads get real crappy, the occasional off road parking job or for snow/ice. So i am not looking for a diamond package here. Just want to know what is beneficial for me to look into before i do all this work. Also, this will be my first transfer case work. I have done small engine rebuilds, down to the block full size engine work, extensive repair work on multiple vehicles for the last 20 years, etc.... so is there anything else i should be aware of?? Seems i will need a new gasket set.... lemme know pls, any info i can get will be extremely helpful. Thx in advance for ur help.

[:)bestgen4runner]

Who diagnosed the actuator as sticking?
There are multiple pieces to this system and I would be 100% sure before replacing the actuator.
What is the actual complaint?
I have replaced several of the actuators, position switches, and front axle actuators. They all can cause issues. 

[SPLfiend [OP]]

Who diagnosed the actuator as sticking?
There are multiple pieces to this system and I would be 100% sure before replacing the actuator.
What is the actual complaint?
I have replaced several of the actuators, position switches, and front axle actuators. They all can cause issues. 

The dealer. "186225. 0.50 transfer case actuator is inop. Need to replace with 4wd ECU" is what the paper work says. Do u have any further insight to this?? Maybe i AM wrong

[:)bestgen4runner]

The dealer. "186225. 0.50 transfer case actuator is inop. Need to replace with 4wd ECU" is what the paper work says. Do u have any further insight to this?? Maybe i AM wrong

First number is the dealer # or tech #
0.50 is the flag time they gave the tech for looking at it 1/2hr
transfer case actuator is inop, Means is not operating
need to replace 4wd ecu is his or her recommendation. or they recommended the actuator and the ecu, LOL

I have never seen a 4wd ecu fix this issue.
there is no way he diagnosed the issue properly in 1/2 hour. My Guess is they guessed and hoped you would not fix in so he can get back to gravy work.

[SPLfiend [OP]]

First number is the dealer # or tech #
0.50 is the flag time they gave the tech for looking at it 1/2hr
transfer case actuator is inop, Means is not operating
need to replace 4wd ecu is his or her recommendation. or they recommended the actuator and the ecu, LOL

I have never seen a 4wd ecu fix this issue.
there is no way he diagnosed the issue properly in 1/2 hour. My Guess is they guessed and hoped you would not fix in so he can get back to gravy work.

So what is ur suggestion??? Do u have one?? Cause so far u have denounced my only lead

[:)bestgen4runner]

I work in a Toyota dealer, Heck I am at one right now.
I just know how the system (stealership) works because I am a apart of it.
I can make suggestions if you would like.   
Just understand that this is a complicated system and you likely are in over your head. 
Let Me know and we can procede. 
Do you own a meter? Do you have a hammer near you?
How many jack stands do you have?
What color is the Tundra? (sorry last one was a Joke)

[SPLfiend [OP]]

I work in a Toyota dealer, Heck I am at one right now.
I just know how the system (stealership) works because I am a apart of it.
I can make suggestions if you would like.   
Just understand that this is a complicated system and you likely are in over your head. 
Let Me know and we can procede. 
Do you own a meter? Do you have a hammer near you?
How many jack stands do you have?
What color is the Tundra? (sorry last one was a Joke)

I am a commercial electrician, so not only do i have a good meter.....i know how to use it....
Im pretty sure i said extensive repairs to multiple vehicles, so yes i have a hammer and several jack stands and a floor jack. But i think u mean something other than a tool "hammer"??
The color is burgandy
May we proceed now??
I know a "stealership" is last resort, but i am stabbing in the dark otherwise. So any and all help is appreciated, as stated before

[:)bestgen4runner]

Ok
working on a car at the moment.
I will type up something for you shortly

[:)bestgen4runner]

So the first thing I would try is the following. (please be careful)
Put the truck up on 4 jack stands all wheels safely off the ground. Place the truck in gear and select 4 wheel high. Rear wheels should be turning.
now go to the front axle and you should see an actuator. that is part of the front axle. tap on the actuator don't go crazy and break it but really tap on it and around it. often the front actuator is the cause of the issue and this is the first step I would do.
if the truck suddenly goes into 4x4 while you are tapping you have found the problem.
let me know what happens and we can move to the next step.
 

[SPLfiend [OP]]

As it is nascar race weekend where i live, i will not be able to get this done right away. Pls allow me a couple days to get at it.

That said, when i first got my blinking light, i was stuck in the mud at the low point of two hills. I worked it over very heavily, trying to get the actuators to move. I beat the poor truck up pretty good trying to get it to stick and never got the front wheels to turn. I had some spectators standing by, watching, and i was hanging out the window. Never could get a front wheel to turn. Turning the switch off and on, jamming it from drive to reverse, etc..... this was my first thought of it being the transfer case actuator.

I will do the hammer as soon as i get the chance. I was told there were two front actuators, one for left and one for right. Then one for the transfer case. Shall i try them each as the other internet forums suggest?? Can u possibly give me more than one step per post? So i dont have to wait for a reply each time i complete one of ur steps. This is my daily driver, so i cant just leave it sitting on jackstands while waiting to hear. Thx

[:)bestgen4runner]

There is only one actuator for the front axle assembly.

[SPLfiend [OP]]

So since i have now done this.....and my half shaft to the front wasnt turning......after working the switch, on and off........now the half shaft is turning, all the time......couldnt ever get the fronts to move....but now the half shaft turns all the time and all the warning lights are on and flashing inside the dash......

I could here a simple beeping coming from each actuator. While BEATING them to get a reaction and while trying to get the transfer case actuator to disengage i had my son turning the switch off and on.

So now my truck has MORE PROBLEMS....

[:)bestgen4runner]

What is a half shaft? Drive line or cv axle?
Did you just tap on the front axle actuator?
What made the front start operating? Did it happen when you tapped on the front actuator?

[SPLfiend [OP]]

The front NEVER worked. The half shaft from the transfer case to the front axle assembly started to turn. NEVER got the front wheels to turn. Pounded on the front axle actuator and got nothing. While switching the truck from 2wheel to 4hi the half shaft from the transfer case to the front axle assembly started turning. Once i decided i was not going to be able to get the fronts to turn AT ALL, i decided i needed to focus on getting the transfer case actuator to move again. As my truck now has MULTIPLE warning lights on and flashing. I beat on the transfer case actuator, to no avail. I could never get the truck completely out of 4hi. So now my truck is stuck with all these lights on and flashing, and it is now dragging down my truck.

Now i may be naming all of this wrong..... but there it is

[:)bestgen4runner]

Its not in 4x4? but the wheels are dragging?

[SPLfiend [OP]]

Now the 4hi light flashes nonstop, the vsc light is on, the hazard warning light is on. The "driveshaft" between the transfer case and the front axle assembly now is constantly engaged. It is not dragging down the truck to the point as if it were in 4x4, but there is a significant change in pickup and throttle response. I can only assume that this is from turning the additional metal that is the transfer case and driveshaft to the front axle assembly. Pls understand, i speak in laymans terms. So if u have a specific term "dragging" or otherwise u r looking at, i assure u that i mean a more simple explanation. As well as, i am now driving it around with the selector switch on 2wheel, same as i usually do, but all of this is still occurring

[:)bestgen4runner]

Disconnect the battery and then try to take it out of 4x4.

[blackdiamond]

Disconnect the battery and then try to take it out of 4x4.

After reconnecting the battery?

[:)bestgen4runner]

yes

[SPLfiend [OP]]

This had no effect. My truck now idles incredibly low, there is a definite "slack take up" from when i press the accelerator to the actually jerk motion of movement in the truck. And now my truck rolls backwards down hill, half the time, while its still in gear...this sucks....i will probably break something else just tryin to get to work tomorrow.....

[blackdiamond]

This had no effect. My truck now idles incredibly low, there is a definite "slack take up" from when i press the accelerator to the actually jerk motion of movement in the truck. And now my truck rolls backwards down hill, half the time, while its still in gear...this sucks....i will probably break something else just tryin to get to work tomorrow.....

I would guess your fuel maps will relearn fairly quickly and resolve these issues.

[:)bestgen4runner]

Do you have a code reader, If so.
pull and record the codes. then clear them and report back.

[SPLfiend [OP]]

No code reader. I will have to use auto zones tomorrow after work. 16 hours from now.

[:)bestgen4runner]

Go buy a cheap code reader.

[SPLfiend [OP]]

No codes, whatsoever. Even had them get out their "nice one" that can read drivetrains (supposedly) and still nothing. The hazard warning light has disappeared but the VSC is still on and the 4hi blinks. I have tried switching it off and on at varying times and speeds but still no response. Now my truck vibrates at highway speeds. Im sure i am doing damage to something, as the manual says dont do over 60 with 4wheel engaged....

[:)bestgen4runner]

Did the throttle response issue correct itself?
 

[SPLfiend [OP]]

A lil. Still seems to have a lil hesitation, waits for things to spool up???

[:)bestgen4runner]

So hear is a review.

You feel like its stuck in 4x4 Hi. (I think you are in 4x4 at lease at the transfer case is)
Vsc light is on constant. (I actually believe this model will turn this light on when in 4x4)
4wd hi light is on constant. (because the transfer case position switch is actually in 4wd hi)
Vibrates at freeway speeds. (Because your in 4x4 hi and front driveshaft is spinning)
There are no codes of any kind. (strange with the hesitation you described and horrible low idle) I suspect its re learning or trying to.
There is a lack of throttle response. (I am guessing your truck has quite a few miles on it and its having a hard time re leaning) This can happen from time to time. Just let it idle and idle and idle until it figures it out.
If it wont relearn then unfortunately you are going to need a factory scan tool (dealer) so they can reset the adaptive memory. You can try to slightly push the throttle to reach the normal RPM it would idle at. This can help with relearn. No promises.

This Sounds like you got it to go into 4x4 hi and is just stuck now.
The part that does not make sense to me is you got the transfer case into 4x4 and the front drive line is now spinning but your not spinning a front tire.

I believe You have multiple problems.

#1 the transfer case should not be stuck in 4x4 when you select 2wd. I am going to assume that the transfer case actuator is actually bad or sticking.

#2 The front Diff actuator is not engaging even though the truck is in 4x4 and based on the lights it knows its in 4x4.

My recommendation is replace the front A.d.d actuator. The one I told you to tap on.
First step. I am expecting that the front wheels will then start to spin as they should.
If you get the part # from your local dealer I might have one. (tester part)

They are expensive.
There is a test procedure but I can tell you now you will say "WTF"
Thats what I say every time I have performed it. There are limit switches in the actuator that can be damaged easily so you have to wire up quite the wasu setup to protect them.

Take it to the dealer pay the $$$$$$$$ and make sure it goes to there Senior tech.

Going to say this again. "I think your in over your head"

 

[SPLfiend [OP]]

This took me a couple of days to respond because i needed to swallow my anger a bit. But ur powers of observation r AMAZING. the part u dont mention is that i was right to begin with, the transfer case actuator IS faulty. As well as i am now worse off, thx to u, i am stuck in 4x4 because of testing it. U keep mentioning that i am in over my head, yet i was able to come to the same conclusion before u even answered. Ur one line answers and lack of full disclosure seems to tell me U might be in over ur head and dont have the true answer other than "it shouldnt do that". Thx fer nuthin. Next time dont be so smug and self righteous. No need to reply, i will never return to this forum again....

[:)bestgen4runner]

Well I am sorry That you feel that way, best of luck.