2006 Tundra 4wd doesn’t work when hot

My 4wd light just flashed multiple times on the dash. I replaced the differential actuator and changed the fluid in the transfer case. The fluid change helped the most. I could now drive it and the 4wd works when it’s cold, however driving about an hour and the 4wd will not engage, the light just flashes. It is way past the normal operating temperature. I took it to Toyota and they diagnosed it as a bed actuator on the transfer case and want $2300 to replace it. Well I bought the actuator online for $325.00 and went to install it. I left the rod in place and removed the gear on top of the actuator. Put it all back together and the truck dash light is either always flashing or in 4wd. I am going to make sure the rod is all the way in and cycle the actuator which won’t be mounted to 2wd and reinstall everything. Hopefully this works. Any insight is appreciated.

 

Pushing the rod all the way forward will throw the Xfr case into 4 low. It could be that the xfr case actuator is out of sync with the front diff actuator. This has been discussed a few times here and its fairly easy to get everything working together again. I'll see if I can find my post on how to sync the 2 actuators.

Oh and welcome to the club!

 

Thank you for the quick response and help. I would of definitely pushed the rod all the way forward bc several locations say that is 2wd.

 

Actually, I had it backwards Elmer... With the rod all the forward it would be 2wd. You are correct.
Here's my notes from another thread. This should help verify.

06 Tundra 4x4 System - LAST RESORT

 

Thx for the reply and clarification. I was almost ready to follow ur suggestion. I will be working on this Sunday and maybe Monday because of the weather. Going to make sure the Rod is pushed as close as possible to the Xfer case(2H) then install the gear. Second, remove the actuator and turn the key to let it cycle with the 2H still being used. Any chance of the spring flying off while I do that? Once the actuator cycles to 2H I will attach it to the xfer case. Sound right? I don’t have anything to clear the codes tho.

 

I don’t recall there being a spring inside the actuator. It’s basically a motor with a worm screw drive that turns a gear to slide the rod in or out. There’s a metal inspection cover on the top of the actuator (not the plastic cover over the electronic contacts) that you can remove which will allow you to remove the gear that runs the shaft in and out. Note the position of that gear if you remove it.

 

Mine is plastic and I did remove it and it fell out so I don’t know the position. Any suggestions?