4wd - I Broke It Properly Now!!!

[ash-ssrg]

Last night I suffered a moment of muppetry that left me near to tears!

First let me explain - since buying my 3rd gen in Oct 2006 my 4wd has VERY SELDOM worked as it should.

I deduced that, when selecting the 4wd switch (H4F):
1) the front diff engages. I can spin both front wheels up in the mud - great!
2) the transfer case engages in, BUT in LOCKED centre diff mode (H4L)- wants to wind up on tarmac - not great.
3) 4wd lights just flash.

So I am basically getting 2nd gen type of 4wd on my multimode 4wd system.

When deselecting the 4wd switch:
4) the ADD (front diff) disengages
5)the transfer case remains locked thus still driving the front propshaft.
6) lights still flash for days/weeks.
7)can still drive wind-up free due to the disengaged front diff.

So, I checked the the actuator switches for continuity - one on the front diff, 2 at back of the transfer case on the shift actuator.All good.

Then ,spotted TonyN and Jonnytoyota mentioned the transfer actuator terminals were a good source of trouble on 3rd gen 4wd systems. when I opened the transfer actuator to check/clean the terminals, the WHOLE gear popped out!!!

I spent hours trying to get it back in - no joy. Don't even know what rotation angle it goes in at. resorted to loosening the whole actuator and can manually move the shaft, BUT ITS ALL A MESS!!!

Sorry for the long post but any advice on this will be highly appreciated.

ASh.

[charvell]

as far as i know the central diff lock should not be used on tarmack even in the 3rd gens. I dont know about the other bit

[Apache]

I'd second that. Never use diff locks of any description on tarmac. The whole point is it will prevent wheels turning independently, so by locking the centre diff, you force your back wheels to turn at the same rate as the front - which aint always so.

The reason you cant use 4wd on tarmac with a 2nd gen is because you dont have a centre diff. What I believe you do by locking the centre diff on a 3rd gen is (kinda) turn it into a 2nd gen drivetrain.

[ash-ssrg]

I do not use 4wd on tarmac - because when I engage the 4wd switch/H4F (4wd centre diff UNlocked), what I get is H4L (4wd centre diff LOCKED).

When disengaging the 4WD switch, the front diff disengages but the centre diff remains locked.

Fortunately for me the disengaged front diff (ADD) cuts the drive to the front wheels.

I Know that the problem is intermittent because in the 3 years of ownership it has actually engaged properly 3-4 times.

I can really do with some help on correctly re-installing the (centre diff) transfer actuator that I managed to butcher.

Thanks,
Ash.

[Apache]

OK, its just point number (2) in your first post, it reads as though that was your intention, but I guess you mean you cant select it WITHOUT the centre diff locking, hence the wind-up.

[ash-ssrg]

OK, its just point number (2) in your first post, it reads as though that was your intention, but I guess you mean you cant select it WITHOUT the centre diff locking, hence the wind-up.

Sorry for any ambiguities there Apache. I'll soon get to grips with this English language malarky ( says the former johnny foreigner).

I appreciate anyone who takes the time out to read my dilemma.

I rang up HRH TonyN earlier - he set my mind at ease a little by confirming that it is a do-able, albeit tricky job to re-assemble the transfer actuator assembly without stripping the whole transfer case. He's done it before and will have a look for the notes he made at the time...... thanks TonyN!

Any other pearls of wisdom from within Surfland would be highly welcome!

Cheers,

Ash.

[ash-ssrg]

No Drive To Rear Propshaft!!!

Got the actuator back together but had no clue if its aligned properly.

Now I've ONLY got drive to the Front propshaft!! Rear drive is DEAD!!

WTF HAVE I DONE??!!

[ash-ssrg]

Got the actuator back together but had no clue if its aligned properly.

Now I've ONLY got drive to the Front propshaft!! Rear drive is DEAD!!

WTF HAVE I DONE??!!

As a backup plan I will be looking at a 2nd hand g/box & transfer box - 500squid!! from a bloke in Manc-chester. Will probably go have a look at it and find its a 2nd gen or somit.

Just what the doctor ordered for an unemployed credit crunch victim!

If mine is completely FUBBAR'ed and I can't get a replacement I may have to seriously consider BREAKING what has to be one of the best looking 3rd gens on the road, IMHO.

All because of a slip of the screwdriver!!!!

[charvell]

i would imagine all you have done is put it back together the wrong way round, did Tony come back to you with a how too?

[KERRSURF]

Take a deep breath dude.

If this happened to someone else, think what you would say to them.

Get the proper advice, take your time and fix it properly.

I wish I could help more in the tech dept but just chill, I have had dilemmas like this myself but a wee bit of calm and planning will get it sorted.

[JONNY TOYOTA]

4wd

Hi Mate My Non Working 4wd Was Fixed By An Ex Toyota Mechanic
At Uk Teknics.i Have Put Quite A Few People In Contact With Him
As He Knows All About The 4wd Queries And Has Fixed Mine.if You Want To Call And Chat With Him His Number Is 07956957387 (wally)
Cheers
Jonny

[ash-ssrg]

Got the actuator back together but had no clue if its aligned properly.

Now I've ONLY got drive to the Front propshaft!! Rear drive is DEAD!!

WTF HAVE I DONE??!!

OK, a BIT of good news - I took a deep breath, put some direct current to the actuator motor to move the solonoid approx 5-10 degrees, clockwise (and thus the transfer shaft backwards slightly) and got rear propshaft drive again!!!

Actually, it is currently in H4F (4wd with open centre diff) lights still flashing.

Rang up/harassed TonyN again who has promised to look for his crib notes on how this lot works and lines up.

Over to you, TonyN.........

[ash-ssrg]

Appeal

Hi Mate My Non Working 4wd Was Fixed By An Ex Toyota Mechanic
At Uk Teknics.i Have Put Quite A Few People In Contact With Him
As He Knows All About The 4wd Queries And Has Fixed Mine.if You Want To Call And Chat With Him His Number Is 07956957387 (wally)
Cheers
Jonny

Thanks Johnny,

Rang Waleed last week - he mentioned that the sorted actuator motors on 2 surfs - one worked (yours), the other did'nt. He did not remove the actuator solonoid though but is willing to have a look/play if all else fails.

All,
Are there any big-hearted 3rd genners out there who who would be willing to CAREFULLY open their actuator casing while in 2wd, take a snap and post as a reference!!

A total of 3 12mm bolts followed by a carefull pry with a flat blade does it.

ASH.

[ash-ssrg]

Thanks Johnny,

Are there any big-hearted 3rd genners out there who who would be willing to CAREFULLY open their actuator casing while in 2wd, take a snap and post as a reference!!

ASH.

Guess not!

Anyways, some moderately good news - I've managed to get the solonoid back in but is probably a few degrees out still.

This is after weeks of bruised knuckles and cursing.
The other big problem is/was getting the correct factory service manual info.

Be warned - this is a job best described as a MUTHER F****R!!!

Has been a good learning curve. At least I can manually shift to 2wd/4L/4F.

Will report back if/when this gets sorted.
ASh.

[stukaneche]

I am having exactly the same problem! It is iso frustrating becuase I had it all working but the lights still showed something wrong, so I persited with experimenting with making small changes to the position of the actuator gear and have lost it again and it is stuck in 4WD however I have swapped the VSV hoses to get it back to 2wd but I am not sure if the the rear diff is locked or unlocked! This is a complete nightmare! Any help would be apprecaited.