T-Case stuck in 4WD

[AssBurns]

My t-case is stuck in 4wd. I’ve tried cycling it between all the options multiple times and it still doesn’t come out of 4wd. Goes into 4lo and 4hi, but never goes into 2wd. It is the multi-mode t-case which I’m guessing is actuator based. I thought it was mechanical shift (like the regular J shift) besides the AWD button, but I guess I was wrong.

Where do I start?

I have a J-shift case with the Bud Built clocking ring, but I’ve never gotten around to making the seal spacer required to make this work without making it leak.

 

[Slim-Whitey]

So. . . So this thing is a button/dial on the dash or a floor shift?

A floor shift stuck in 4x4 is usually a mechanical issue. Pads on the shift fork worn or gone completely, a synchro ring chewed up, bent linkage etc.

If it's electronic, it's almost always a stuck actuator.

Is the t case physically stuck in 4x4 (as in, you can't free spin the front driveshaft with the front wheel lifted off the ground), or is the 4x4 light just stuck on?

 

[TeamPez]

Been in any water lately? My 02 did the exact same thing after I dropped through the ice on the South Platte. The breather tube had come off the transfer case actuator motor and filled it with water. Made the electronics in there unhappy. Pulled it off, drained it and reattached the breather then replaced the o-ring. That was after a week of trying everything else. Also if you pull the TC actuator motor off to dig around remember it is clocked. Had to stick it back on right of proper alignment then twist it left to "clock" and line up the bolt holes. Found several write ups with similar symptoms. TC sensor switches being the most common issue. If I remember right there are like 4 or 5 on the TC. Couple easy to get to and a couple PIA up on top. 96-00 vacuum rigs seemed to have a switch go out up at the front actuator. Seemed like an easy fix once they isolated the bad switch with a multi-meter.

 

[4runner DOA]

I meant to respond to this and totally forgot. Have you put it up on jack stands on all 4 yet and tried popping it in drive/neutral/reverse? Could be binding somewhere and a little free wheeling might free it. Popular option in the 4th gen is smacking the actuator/transfer case with a mallet, but the add controls 4hi/2wd doesn't it? Maybe the add is stuck? Someone mentioned the breather tube letting water in too. Don't remember if yours has a center diff lock, but could be the center diff isn't completely disengaged as well.

 

[AssBurns]

Okay so I put it on all 4 wheels and at first it was stuck in 4wd. I pulled the actuator out a little, and took the internals apart (not the actual motor, but the gear covers and gear thing). After that it is now stuck in 2wd. Goes into low range no problem, but its still 2wd (2lo).

So the multi-mode case does hi/lo mechanically, but 2wd/4wd/AWD is all electronically controlled via the motorized actuator. Fucking lame.

I also remembered I had this PDF file about transfer case construction that I found a while back and forgot I had until this evening.

 

[TeamPez]

Did you clock the black cover when you put it back on? If we are talking about the same cover on TC actuator motor. When I put mine back together I stuck it straight back on which put it out of timing with the front actuator or something like that. Also be careful with that O-ring cause it's a bitch to get back in properly without it cutting during tightening. If you fuck it up let me know. I ended up with quantity of like 20 when I replaced mine.

 

[AssBurns]

Did you clock the black cover when you put it back on? If we are talking about the same cover on TC actuator motor. When I put mine back together I stuck it straight back on which put it out of timing with the front actuator or something like that. Also be careful with that O-ring cause it's a bitch to get back in properly without it cutting during tightening. If you fuck it up let me know. I ended up with quantity of like 20 when I replaced mine.

I didn't pull the black motor cover. I pulled the gear covers and all looked good. I think the motor is bad because I didn't even hear or feel it trying.

 

[theesotericone]

I didn't pull the black motor cover. I pulled the gear covers and all looked good. I think the motor is bad because I didn't even hear or feel it trying.

Just chuck that multi mode case and put a j-shift in. Problem solved.

 

[Jaysen4runner]

The last time I diagnose a stuck t case multiple mode. The case is broken internally and had to be replace, motor wasn't working either.

 

[Dukestaco]

. My son's t case was doing the same thing but his is a second gen Tacoma. We did the FJ T case swap. No more actuator problems.

Pick one up at the junk yard and swap it in. Then fix the one you have. One in play and a back up.

 

[AssBurns]

Yeah I’m gonna have to do something ASAP since KOH is coming up quickly.
I would like to swap in that J-shift I have, but I gotta figure out that seal issue first.