Center is locking and so is the front but rear will not lock. I didn't actually have to pull the CDL indicator switch. While messing around with it in the driveway, I engaged 4 low, pushed the center diff lock button, put it in reverse and slowly backed up. CDL light came on within about 6 inches of rolling backwards. It never flashed before hand, it was off until it locked then on. I repeated this a few times and it will lock up every time. Next engaged front/rear lockers and front locked up within a few seconds, I was rolling forward very slowly and it popped right in. The rear would not lock. I took it over to a dirt road and did circles for a bit with rear lock only but no luck.
While testing all of this out I found I have another issue. I must not have packed the driver side birf well enough because when I lock the front and attempt to turn it pops pretty bad. It only does it with the front locked, I've never heard it while driving around under normal conditions even in sharp turns. So questions... Will just adding moly to the knuckle solve the problem? I pulled the plug yesterday and it looks to be about half full. From what I remember from the manual it should be 3/4 full. I am going to pick up another tube of the same stuff I used to rebuild with and add some, 1/4 tube at a time, to see if that helps. When I did the rebuild I didn't swap the birfs sides and now I'm wishing I did. I only have 65,000 miles on it so I thought I could wait until the next time around. If adding moly doesn't work I'll order some gaskets and pull the birf and repack it.
I also have a cluck noise that only occurs on turns when I have a little bit of body roll. I can feel it directly under my feet. I'm thinking it may be lower control arm bushings. The rear passenger side bushing doesn't look to good and the bushing sits over to the far left side of the rear hanger. So plan is to start there with bushings and I'll take it from there if the noise is still there. (I've already gone through everything and made sure nothing is loose)
Changed rear diff fluid which turned out to be more of a job that I had expected. Drain diff, then go to pull fill plug and notice, oh
, it's totally stripped! In the future I'll be sure to pull fill plug then drain plug to make sure I don't end up stuck with a drained diff and no way to add fluid... Ended up welding a piece of 1" square tubing to the plug so I could get a wrench on the tubing to pull it out. Filled it back up put the bad drain plug in and drove to the toyota parts dept this morning and picked up a new plug.
Never a dull moment...
