carkivey3

trying to help my son with his 99 4runner 4wd. the front axle will not lock in. the transfer case locks in as the driveshaft wont turn while in park and does turn while in drive.i get solid green lights on dash showing everything locked in.my vsv valves put vacuum to the front actuator properly(both to shift to 4wd and to disengage). i put handheld vacuum pump on and it shows no leakdown. if i start in 2wd with both vacuum hoses off and shift to 4wd i get the green flashing lights on dash as the front add switch is not yet made. i put my vacuum gun on engage hose and pump and the front actuator must shift as now i get solid green lights on dash. my front axle is still not engaged. i can consistently repeat this test. this tells me the actuator is shifting but maybe internal linkage or sleeve is bad. i have searched this site and others trying to find pics or anybody who has actually been inside this actuator before i start taking apart as i want some idea of what i will be getting into. can someone please advise? thanks

Nelsonmd

I just took mine apart to service, see here: http://www.toyota-4runner.org/3rd-ge...servicing.html

There isn't much to the actuator, there's just a shift fork in there that grabs a sliding gear in the diff. It sounds like you may have a broken shift fork or locking collar if your actuator is actuating but it isn't locking the axles.

Taking the actuator off isn't too bad. You can do it without taking off the steering rack or the diff, but it is a bit squirmy to get the actuator in an out. I was able to do it, but it took a few minutes each time to figure out how to rotate it around the rack, frame, diff, and sway bar. And watch out for the little vacuum port on the outside, I bent mine a bit shimmying it out.

It uses a liquid gasket seal, so pick yourself up some gear-oil safe gasket maker.

carkivey3

thanks nelsonmd. that link helps a lot. a visual helps more than than a write-up. hopefully we can get back together soon when we both have time and remove actuator and know for sure whats goin on.