05 Sequoia - 4WD Actuator - HELP (1 Viewer)

[sirdewitt]

In need of some HELP..... My 05 Sequoia was having the symptoms many have reported with trouble going into 4WD LOW. 4WD HIGH shift was working fine but the shift to 4WD LOW would never complete. The 4WD LOW light continues to flash and there was a beeping from the 4WD Actuator mechanism located on the transfer case. I tried all several times and many tactics to jar the shift mechanism free in order to allow the shift to 4WD LOW to complete. With no success I dug deeper.

Thinking that the issue must be something in the Actuator mechanism, I proceeded to take the cover off and investigate. Without having my good analysis and debugger hat on I proceeded to disassemble some of the components inside the actuator. I was able to move the rack shaft back and forth shifting the tranfercase manually from 2wd to 4wd HIGH and 4wd LOW. The mistake I made was not noting the alignment of the gears that I removed from the actuator case. I know….. DUMB >>> DUMB >>>> DUMB…… but it is all water under the bridge now.... :whoops:

Anyhow, fast forward to today…. I have since determined that the root cause for my original problem was most likely the cracked vacuum hose on the top of the actuator. Now…. If I could only get the correct alignment/orientation of the gear inside the actuator so it functioned properly.

Does anyone have insight to the correct setup of the internal components inside this switch ? The correct orientation... gear to gear and sensors is critical to proper operation.

Thanks for any help... including pictures of a unit that has not been dissassembled.

Trying to avoid an expensive trip the the STEALERSHIP for repair of this unit

 

[ToyotaDon]

You probably would not even be helped by the dealership, they would just sell you a new actuator as Toyota does not provide service info for rebuilding these. Unfortunately, the only way to replace the whole actuator requires removal and disassembly of the transfer case.

To add to that, the "vacuum hose" you see does not have anything to do with the actuation, it is a vent hose. I think you are stuck with either figuring out how to reassemble and realign the actuator, or plan on replacing the whole assembly.

Hope someone else can chime in with better news.

 

[40Habits]

This is off a 4Runner but it should have the same actuator. I hope it helps!

http://www.ncttora.com/fsm/2003/4runner/215/ncf/1gr-fe_transferconstruction.pdf