Writeup: 1988 FJ62 4WD Solenoid fix for $17.77
- Thread starter Randy88FJ62
- Start date
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@4Cruisers donated his unused transfer vacuum hard lines in heartfelt efforts to keep cruisers cruis’n! Thank you!
Slipped them into the line up at work today for powder coating.
Don’t want these guys rusting like the old set!
Also found that the newly adopted creature has taken a shine to the Landcruiser, and may be willing to lend moral support when needed.
Slipped them into the line up at work today for powder coating.
Don’t want these guys rusting like the old set!
Also found that the newly adopted creature has taken a shine to the Landcruiser, and may be willing to lend moral support when needed.
Worked like a charm. From a new 62 owner, Thanks!/ Problem: 4WD light stays on.
1. Check the front driveshaft under your car. If you press the 4WD button to the off position in your car and you can't turn your front driveshaft then your solenoid is probably burnt out.
4WD VSV Replacement: Toyota P/N 88690-89132
Part Name: Valve Assy, Magnet
Price from CruiserDan: 17.77
No Discount Price from Toyota: 23.70
This part is off a 1988 Toyota Pickup. It's off the 22R Engine.
Tools Needed:
1. 12 mm wrench or socket. (unbolt VSV bracket from firewall)
2. Screw driver (remove bad VSV from bracket)
3. Angle grinder or file or hack saw (modify metal notch on VSV to fit original bracket.)
4. File, pocket knife, or razor blade (remove connector lip to fit original clip)
For reference: VSV = Vacuum Solenoid Valve
Steps to repair electronic 4WD in an FJ62 (mine is a 1988)
1. Remove Bad VSV (red one) This picture shows the passenger side firewall. You need a 12 mm wrench to remove the bracket. Unclip the wires and hoses. Make sure to label everything or keep it half hanging and connected like I did.
2. Unscrew the new bracket from the new VSV. We don’t need it. Also, take off the 2 hoses that come with the new VSV as well (not shown in pics)
3. Now we need to modify the new VSV before it will fit. Compare the two VSV’s and it’s obvious that we need to trim the metal tab on the VSV and remove the lip off the new electric connector. I had already trimmed mine prior to this picture so use your imagination.
This second picture shows the two metal tabs. They are different sizes. The new one is too big and needs to be trimmed down.
Wear safety glasses and use proper tools and techniques. Don’t stab yourself with a pocket knife while trying to remove the electrical connector lip. Point is, be safe.
4. Now that you’re new VSV is modified; check to see if the electrical connectors fit. Also check and see if the metal tab on the VSV fits into the firewall bracket you unbolted. Connect up the proper hoses. The vertical hose coming straight out the old VSV is the Vacuum line one. The new VSV Vacuum line is the one on the outside. I hadn't trimmed the metal tab yet, so again, use your imagination. Sorry for the lack of proper pictures.
5. Attach everything and don’t worry about sucking on the tube or switching hoses anymore! I have only just installed this. ***DISCLAIMER: Worst case scenario this VSV may burn out early. Who knows, maybe it’s not supposed to be used for this. I hold no responsibility for you trying this. I tried it and it works but I cannot guarantee for how long. My guess is that everything will be ok but I’m just letting you know, do this at YOUR OWN RISK.***
Keywords: four wheel drive solenoid, VSV, vacuum solenoid valve.
Here in 2020 saying a massive thank you for this fix! Worked like a charm on my 88 Sahara
- Thread starter
- #145
I can't believe this thread is still active 12 years later! Glad the fix is still finding people in need.
Alright I've read I think every related comment and post on here about FJ 62 4wd problems and I'm somewhat confused/possibly got it figured out. I just purchased a 1989 FJ 62 from Missouri. Upon purchase I pushed the 4 hi button and light lit up and I verified by driveshaft it was engaged. Now that Im home in Texas I've been playing with it a little more. After locking hubs and putting in 4 high everything works fine but when shifting to 4 low the light goes off and the front end is not engaged. After reading everything on here and inspecting what was going on I swapped the hoses on the VSV's located on the firewall but this is what I have now. Push the button for 4 high. Engages and light is lit. Switched lever from 2 hi to 4 low and the light remains lit and in engaged in 4 wheel drive low. Verified everything by driveshaft, but when I push the 4 high button to off the light goes out and the driveshaft spins freely. My main question is does the 4 high switch have to be pushed for high or low to work? I've read multiple comments on here that it should shift into 4wd low by going from 2hi to 4low on the level and not even touching the 4 high button. I want the system to work correctly and if this is how its supposed to work then great....if not then what might be the problem????
- Thread starter
- #147
The 4WD button and your 4Lo Linkage shifter have no relation. When you shift into 4Lo it doesnt care whether the button is pressed or not.
Alright understood.....regardless that I have 4hi and 4lo I still want everything to operate the way it should. Without pressing the button and shifting into 4 lo I essentially have 2lo. I just have to diagnose what the issue is with it not engaging 4wd when shifting into 4lo. Thank you for your help!
So I recently learned that my 4WD was not working on my ’88 FJ62. The 4WD green light did not light up when I pushed the transfer button in. After reading this thread it sounds like another solenoid problem…
I followed @RECRUISER and replaced my RED solenoid with a new OEM VSV 25860-62010 for $15 on eBay. It snapped perfectly in place and took less than 5 minutes. The green light immediately turned on.
However…the light only turns on when the transfer button is in the OFF position. Strange. And when I push the button to the ON position, you guessed it, The light turns off.
It seems like the solenoid definitely fixed the problem for 4L bc the front wheels engage after shifting into 4L (on the linkage shifter) and locking the hubs, which was not the case before the replacement. I only had 2WD regardless of hubs/linkage shifter position.
BUT it seems like 4H is not engaging. And the indicator light is always opposite whatever is supposed to be functioning.
Can anyone shed some light on this? Am i missing something very obvious?
Should I try to replace my other solenoid (BLUE)? if so, which part would work with that?
Thanks!
I followed @RECRUISER and replaced my RED solenoid with a new OEM VSV 25860-62010 for $15 on eBay. It snapped perfectly in place and took less than 5 minutes. The green light immediately turned on.
However…the light only turns on when the transfer button is in the OFF position. Strange. And when I push the button to the ON position, you guessed it, The light turns off.
It seems like the solenoid definitely fixed the problem for 4L bc the front wheels engage after shifting into 4L (on the linkage shifter) and locking the hubs, which was not the case before the replacement. I only had 2WD regardless of hubs/linkage shifter position.
BUT it seems like 4H is not engaging. And the indicator light is always opposite whatever is supposed to be functioning.
Can anyone shed some light on this? Am i missing something very obvious?
Should I try to replace my other solenoid (BLUE)? if so, which part would work with that?
Thanks!
- Thread starter
- #150
demimoore88,
The 4 HIGH is a separate vacuum actuated system. 4 LOW is manual linkage. So your 4H and 4L systems are completely separate.
Show us a picture of your firewall where the vacuum solenoids are and their routing. You may have something mixed up.
The light coming on when the switch is not depressed is stumping me. hmm. Download the FSM Chassis manual and go to the transfer case section and start checking. Page TF-34.
The 4 HIGH is a separate vacuum actuated system. 4 LOW is manual linkage. So your 4H and 4L systems are completely separate.
Show us a picture of your firewall where the vacuum solenoids are and their routing. You may have something mixed up.
The light coming on when the switch is not depressed is stumping me. hmm. Download the FSM Chassis manual and go to the transfer case section and start checking. Page TF-34.
Last edited:
- Thread starter
- #151
- Thread starter
- #152
- Thread starter
- #154
I don't see any mistakes comparing it to my first post picture or another person's picture on page 8.
Hi All,
I’m a noob at wrenching and the FJ62 1988 is the rig that I have to learn on. I was recently gifted it from my father in law who just passed away.
It needs all the maintenance to be updated, but it starts and runs.
I pressed the 4wd hi button and now the light doesn’t turn off.
My noob question is what is the driveline that I need to turn to see if it’s locked in 4wd hi or not? Im not sure what to look for or try to turn. I’m not sure if it’s in 4wd hi right now or 2wd, but the green 4wd light is on. I’m just trying to prevent any damage or harm to me or the rig. Thanks so much for tolerating my noobness everyone. I’ll be DL or ordering the FSM soon.
I’m a noob at wrenching and the FJ62 1988 is the rig that I have to learn on. I was recently gifted it from my father in law who just passed away.
It needs all the maintenance to be updated, but it starts and runs.
I pressed the 4wd hi button and now the light doesn’t turn off.
My noob question is what is the driveline that I need to turn to see if it’s locked in 4wd hi or not? Im not sure what to look for or try to turn. I’m not sure if it’s in 4wd hi right now or 2wd, but the green 4wd light is on. I’m just trying to prevent any damage or harm to me or the rig. Thanks so much for tolerating my noobness everyone. I’ll be DL or ordering the FSM soon.
My noob question is what is the driveline that I need to turn to see if it’s locked in 4wd hi or not?
- When the 4WD light is lit, and both front hubs are unlocked, you should not be able to turn the front driveshaft by hand.
- When the 4WD light is off and both hubs are unlocked, you should be able to turn the front driveshaft by hand.
WoodnotRust
SILVER Star
Where do I go from here? I tried to use 4WD high the other day, but noticed that my light didn't turn on and I couldn't tell if the transfer case engaged the front axle.
Note, we just got 12" of snow, so I haven't crawled below the car to do the drive-shaft tests yet. I know I have to do this, but before I do can one who knows comment on my question below...?
After reading through this post I thought it might be a solenoid issue and for $16.36 I was ready to buy . But, it appears that the previous owner added aftermarket solenoid valves and may have cut off the connecdtors from the wiring harness. Can anyone look at the picture and suggest the best way to return to "OEM" toyota solenoid P./N 88690-89132 as @Randy88FJ62 suggests? Do I start by trying to find the original bracket? Thanks, Roger
Note, we just got 12" of snow, so I haven't crawled below the car to do the drive-shaft tests yet. I know I have to do this, but before I do can one who knows comment on my question below...?
After reading through this post I thought it might be a solenoid issue and for $16.36 I was ready to buy . But, it appears that the previous owner added aftermarket solenoid valves and may have cut off the connecdtors from the wiring harness. Can anyone look at the picture and suggest the best way to return to "OEM" toyota solenoid P./N 88690-89132 as @Randy88FJ62 suggests? Do I start by trying to find the original bracket? Thanks, Roger
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You should be able to put the Toyota connectors back on those wires, I don't know if they're available new but should easily be able to find used ones and install with new terminals to have a factory-looking install instead of some spliced wire ghetto-ness.
Shoot me a PM, I have an FJ62 in the shop to reference, I have a assortment of new Toyota terminals in stock, and I have a bunch of connectors off a desmogged 80 and I was kinda thinking the VSV's on the 80 smog system looked a lot like the FJ62 4wd guys. Maybe they're the same connector. I'll try to check tomorrow
Shoot me a PM, I have an FJ62 in the shop to reference, I have a assortment of new Toyota terminals in stock, and I have a bunch of connectors off a desmogged 80 and I was kinda thinking the VSV's on the 80 smog system looked a lot like the FJ62 4wd guys. Maybe they're the same connector. I'll try to check tomorrow
red66toy
Supporting Vendor
On this subject, is there a good resource for finding part numbers for different terminals for the 60 series? I know some connectors and terminals can be purchased as stand alone units from Toyota.
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Not to my knowledge, I have the Toyota book for 1996-up but that leaves out 60 stuff obviously, I've had decent luck bypassing Toyota numbers and going straight to the Sumitomo or Nippon books and their numbers, it really helps to have a good relationship with someone who lives and breathes connectors if you're going to do this stuff regularly. Maybe someone like @Onur can shed more light on how to find connector numbers easily. On some of the big ones I've seen actual Toyota part numbers molded into them which is neat.
Somewhat off-topic but I have nearly everything sourced to be able to completely restore a 3FE engine wire harness (replacing everything that regular melts or cracks anyways), I have really come to love wiring connectors, terminals, tracing out schematics, etc in the last few months
