transfer case actuator

4hi lite blink on dash, dealers says the 4x4 transfer case actuator is probably bad, est 2700.oo to fix. is this a DYI project or best to have dealer do it...

 

For $2,700 it would have to be a DIY project for me!

 

Here's the actuator, in case you want to give it a shot.

https://parts.toyotaofcoolsprings.c...or-4140034020/?c=aT04NDMyMzc1NSZyPWxheWVyXzE3

 

$2700 for a $200 part....

I'd do that myself if it killed me, or if I had to spend $2500 on tools to do it. At least i have something to show for the money instead of a free coffee while waiting for the dealer to rip me off

 

Took forever trying to fix my actuator so I am posting the timing for people in the future. Vacuum hose had disintegrated rust on motor, gears and grease. Cleaned contacts, did a dab of solder, added dielectric grease.

 

I just got the cost from Toyota for tranfer case actuator replacement on my Sequoia...$1650 just for the actuator assembly!! I assume this assembly is the electrical & mechanical side. I don't think the $200 actuator listed previously in the thread is the correct part...looks more like the front axle driveline actuator
Gets better!
To replace the whole assembly, requires tranfer case disassembly.
I'm going to pull the suspect cover that the Toyota tech said was corroded. He thinks water got in there. I think that's a design deficiency!
Why does Toyota not sell the cover you repaired?
I hope to see similarities to what you had & hopefully I can rejuvenate it the same way.
If its too far gone then its cheaper to just replace the whole tranfer case. Really Toyota!?
Thanks for your timely & informative post!

 

Nlt sure where you are located but the last time i looked it was pretty easy to find a whole transfer case in a junk yard for $250. It'd be much easier to take apart a working one and clean it up than try to repair one that isn't working. Plus you would have lots of spare parts.

 

Hi Dr_Al,
I found out that the Tundra T-case is not compatible with the same gen Sequoia...I suspect gearing but maybe it is external related?
I may want to hunt down a Tundra T-case still, if my electrical cover is beyond saving. I have a feeling that cover component would be identical. Not any Sequoia T-cases in South AZ.
If I have to get a used T-case then you can be sure I'm keeping my old one for a rainy day.
Thanks for responding!

 

The Sequoia's transfer case is designed to be used in 4wd on pavement. It has a built in limited slip to allow the front wheels to rotate at a different speed while cornering. The low range gearing could be different but I don't know why.

 

So is it considered a part time all wheel drive?

 

Oh! So that explains the limited slip gear oil requirement that the service coordinator could not explain. I had Toyota do the troubleshooting & T-case oil...then I found this forum while recovering from repair estimate shock.
I just need to find a decent Sequoia PDF service manual...been working off a Tundra e-service manual. Fine until I move past the front passenger doors.
The limited slip system probably better accommodates the original intended use for soccer game logistics & groceries runs on slick roads. : ]
See how my inspection/repair goes tomorrow.
Thanks again!

 

My 08 Sequoia has a center diff-lock. So I think that overrides the limited slip mode intended for road operations.
By the way, that diff-lock works very well in the deep soup that I encountered on a winter offroad adventure! Got me well away from the crowds.

 

So, I am NOT seeing where the transfer case requires disassembly.
Looks like the shift fork shafts will slip right through the holes of the shift actuator body once you remove the 2WD-4WD & 4WD-4LO cover assemblies (they each contain a motor & worm gear that push/pull the shift fork shafts) that interact with the planetary gear assembles that carry the 3 electical electrical contacts. I did not get a picture of the fork shafts due to my extra vigilance, mixed with panic, when the lower lower planetary gear fell off due to gravity. I wanted to ensure I reinstalled that planetary gear as close to the original clocking position as possible.
I will attach some more pics later this week.
There is a cheesy rubber vent hose connecting to the top cover assembly on the actuator. Mine had no clamp and the rubber was all rotted near the end. It was disconnected when I looked up in there.
HIGHLY recommend taking a look at that hose!! If it comes off then you have a direct path for water/contaminants intrusion. Appears to be the cause of some corrosion in my acuator covers.
You need to remove the thin metal shrouding to access the shift actuator that protrudes off the back of the tranfer case.

 

I redistributed some of the grease on all of the gears and the electrical contacts. System is working very well so far.
Is there a place to get the same conductive grease used by Toyota? I read some where not to mix different conductive greases.

 

https://www.tundras.com/threads/g2-4wd-actuator.47592/#post-1268229

 

Hank!
Awesome info, thanks!
Confirmed my theories & put my mind at ease regarding what I experienced during upper & lower actuator cover assy reinstallation.

So far so good since the investive repairs on my Sequoia!