Homeslicee

Hello everyone, new to the forum. I've got a manual trans 1990 4runner v6 3.0 200,000mi. I have owned it for 15+ years and have never used 4wd before. I decided I would give it a shot and test it out, but it will not shift into 4wd at all. from H2 to H4. the shifter has a bunch of play so i'm not sure if thats normal or not but I cannot figure out what it may be. Most information I have found about 4wd issues are about 4wd not engaging after shifting into it but I can't even shift in the first place. Vacum lines are good, I will do a second pass again tomorrow. Any suggestions or help is much appreciated!

millball

manual, or automatic transmission???

Homeslicee

MAnual transmission sorry forgot that

millball

The lever should pull straight back into 4 hi. Then a switch on the transfer case should energise a vacuum switching valve that shifts the ADD collar on the front differential.

The 4WD light on the dash will not illuminate until the ADD collar has actually shifted into engagement.

Homeslicee

Thats the thing, my lever does not pull straight down into 4hi. I can't tell what position its in since there is decent play with the lever. Can it be stuck in h4? I can push the lever up towards 2 hi and also move it to the right towards 4 lo. but there are no lanes that the lever follows. its just free movement. i don't feel the lever making contact with anything in the transfer case. It's as if its in neutral.

millball

Have you ever had the clutch changed, or had the transmission removed for any other reason???

If so, it's possible that the transfer case shifter was reinstalled improperly.

Homeslicee

Yes I had the clutch changed once before so its possible. Ill start looking into that then thanks so much for the info! Much appreciated.

millball

Please follow up, and let us all know what you find.

87-4runner

Homeslicee

So I took apart the shifters. It shifts! so im not sure why it was not grabbing the gears. maybe a spring issue? or the grime was lifting the knob high enough to not make contact with the gears? Sorry for massive pictures

removed shifters. very dirty in the transfer case shifter.

grime

removed cover on transfer case shifter

inside transfer case from shifter opening.

last mechanic left a bolt out and stuck at an angle.

Shifted into 4hi

shifted into 4lo

dirty transfer case shifter

spring under shifter cover

spring is slightly bent

superex87

There should be a bushing under the round ball part of the shifter. Order new ones for both the transmission and the transfer case from marlin crawler. Truck will shift like it’s brand new. No slop at all.

millball

That's not dirt under the transfer case shifter, it's a completely disintegrated shifter bushing.

Get a heavy duty replacement from Marlin Crawler, as said above.

scope103

Nice photos. Thanks.

Homeslicee

Fixed! So Millball had it right, the shifter was reinstalled wrong. Took it apart cleaned it out put it back together making sure to shift it back and fourth between 2H and 4H in-between installation to make sure it was seated in the right spot as I tightened everything back up and put it back together. I forgot to take pictures of the shifters seated and installed I completely forgot at the moment. thanks so much for the info! I'm a complete noob when it comes to fixing cars it never crossed my mind to check the shifters lol


cleaned out transfer case shifter

Both shifter plates cleaned out

cleaned the shifter ends


cleaned the mounting area

replaced with stock bushing. Sadly I didn't receive the Marlin Crawler suggestion in time.

4WD shifts nicely! transmission shift is like butter now that it actually has a bushing.

5 Fists

Great thread and great pictures of everything! Nice work.

87-4runner

Well done gents !!!

SomedayJ

Glad you solved it and thank you for the update.