I have a 96 4Runner Limited (automatic transmission) with the 2-4 selector switch on the t-case shifter.

4wd not working, not getting any light in the dash. Bought new VSVs, new 4wd ECU, new vacuum lines, even pulled the front diff actuator and tested it with a vacuum pump.

Things are pointing to my transfer case actuator.

My understanding is that when I shift into 4lo, 4hi, or even neutral, this shaft (not sure what the proper name is) is supposed to move in or out depending on how I shift. I tried shifting into all positions and the shaft never moved. Is this shaft supposed to move when I move my shift lever? Or is the shaft supposed to be moved by the motor inside the actuator?

 

Don't know if I can be of any real help re shaft moving. I have same 4Rnr and same problem. After checking everything you have I checked the actuator motor which worked. So led me to the actuator itself. I had my wife continually push the button on and off while I tapped the case by the actuator and after a few minutes it went in to 4WD. Now my problem with answering your question is that I don't know if the shaft itself moves or whether there is something on the shaft that moves. But apparently if you don't regularly use the 4WD the shaft area grease or ?? can change so that it keeps whatever moves from moving. Sorry not saying this very well. Here is link to another article with similar problem. Hope this helps.

 

Sorry, forgot link: https://www.yotatech.com/forums/f2/h...tuator-195344/

 

Yes, the job of the transfer case actuator is to push that rod in or out, which shifts into 4wd. For what it's worth on my 99 ltd I was having the 4wd light issue and the problem ended up being both a bad sensor and also a bad wire in the harness going into the actuator, which was giving intermittent signal. Might be worth it to pull off the cap on the large barrel portion of the actuator and check continuity between the plug contacts and the contacts inside the barrel. Also check continuity while manipulating the harness to check for intermittent connection. I ended up replacing all the wires and re-soldering them to the existing harness, which fixed my problem. It did require pulling out and repotting the assembly.