Transfer case actuator trouble on 2017

I was up in the mountains last week on a fishing trip turned serious 4x4 adventure. The Jeep and Razor/Side x Side folks couldn’t believe that a stock Tundra could get there. Upon returning to a decent gravel road, I couldn’t shift out of 4low. I tried all the usual things, backed up, turned wheels, and all such. Tried repeatedly over a couple of miles, then stopped to let it cool down some and even disconnected the battery to see if maybe that would reset something. Still didn’t work. Continued on another mile or so stopping often attempting to shift to 4hi, still no joy. Out of frustration I stopped, crawled under, and tapped around on the transfer case and related parts with a hammer (no, I didn’t beat on it…) and after a couple of shifting attempts and a loud “Clunk”, it shifted to 4hi and then to 2hi and I was back on my way.

In the Gen 2 section there is an extensive discussion of transfer case actuator trouble, but only one post (that I could find) on the later Borg Warner type. That post is very helpful and includes what appears to be factory replacement instructions, but I wonder if anyone has had similar issues with their Gen2.5 and if there are repair possibilities ( like on the Gen2) as it seems that no one other than Toyota has the part and it is pretty pricey.

 

I haven't read the post on the Gen 2 forum, but is it working ok now? My understanding is the best maintenance is to actuate it fairly often. Maybe monthly put it into and out of 4wd/Lo to keep things moving. If yours is working maybe increase your frequency of actuating it.

 

Since I am back in 2hi and need the truck, I haven’t messed with it any more. I’m afraid if getting stuck in 4 lo again…

At the beginning if the 4x4 adventure, I shifted back and forth between 4hi and 4lo several times and it shifted smoothly. I did make several water crossings after deciding to leave it in 4lo. Maybe water in the shift motor?

When I get this worked out, I definitely will do the monthly 4x4shift exercises.

Thanks

 

How old is the fluid? Just curious.

 

About 60k. Probably should be thinking about changing it.