Hey maybe you all have some suggestions, I have a 94 4runner with ADD hubs, 5 speed manual . I can shift into 4 wheel drive no problem, when I try and take it out of 4 wheel, it does not want to go back to 2 wheel. I push the lever back up and the light does not go off, nor does it engage back into that position, here is the kicker, I can get it to engage back into 2 wheel if I make a fairly sharp turn, or I go into reverse. Any Ideas what would cause this.

Oh when it does engage back into 2 wheel I can here it click into place.

EDIT:SEE BOTTOM FOR SOLUTION TO PROBLEM

 

the ADD is actuated by vacuum. when you shift into 4wd the vacuum is used to pull a sleeve over and lock the front axels. the 4wd light doesn't come on until the sleeve is pulled over (sometimes the splines don't line up right away, so it has to wait until everything matches).

likewise, when you shift out of 4wd, there may be some strain on the splines so the sleeve can't slide away instantly. driving in reverse or turning may be enough to release the pressure. once the sleeve can move, the 4wd light turns off. but as soon as you shift out of 4wd, the transfer case has disconnected so you're really not in 4wd anymore. it's just like being in 2wd with the hubs locked.

i did a quick and dirty explanation of add here, if you need more, there's a bunch of info around here if you want to search for it.

 

I did do a search, but here is the thing, when it is in 2 wheel there is some effort required to pull it down into 4 wheel, not a lot just a little. When I push the lever back up out of 4 wheel, it does not push all the way like it is rested in the normal position, and I can feel that it is still in 4 wheel by the way the truck drives. THen when I make that semi sharp turn I can here it click or pop backinto place. Could a vacuum line leak make this happen

 

i believe that the add transfer cases have a synchronizer for the front drive shaft to spin it up to speed so it wont grind, just like the effort needed to shift gears, i think that your transfer case/add system is working ok, when you disengage it from 4wd, you disengage the transfer case from the front drive shaft, but the sleeve in the front diff has not slid over yet, but the axles are still turning the drive shaft, when things are just right the stress on the sleeve is relived and it slips over

 

Mine was sticking like yours when I got. I just backed up to release the stress on the driveline...which is fairly common in other makes, like Izuzu. But when I switched to synthetic fluids in the front diff and transfer case the problem went away. Might be time to swap out all your tranny, transfercase, front and rear diff fluids.

 

The fluids were just all replaced. I just got the runner in Jan or so. I had all the differentrial fluids chagned the tranny flushed, but I did just have some work done on the transfer case(A tranny shop replaced all the seals, they were leaking). I remember it was kind of difficult to get it back out of 4 wheel before but only used it like twice before. I think I will take it back down there and tell that since they worked on it I am having this problem.

 

I agree, I would take it back to the shop and tell them that you started noticing that problem after you got it back from them and see what they say...if its a good shop they'll offer to look at it for free.

Fink

 

Maybe the shifting linkage from the shifter to the t-case needs adjusting. I had a similar problem after I did my body lift.

 

Ok I got it fixed. He is what the problem was. I had 3 different types of tires on my rig and recently had them all changed out for 4 brand spankin new BF Goodrich all-terrain ta's (lovin em, if your in the market for a tire this is the one!) Well since I have had the new tires on the problem is gone. I think the those front two tires being different might have been rotating at a slightly different speed and causeing some binding. Now that the tires are exactly the same the problem is gone. Shiffing on the fly like a champ now.