06 Will not disengage 4wd HI, ECU clicking

If there was water, check the vent hose.
And definitely get a gasket / seal on there.
You don't want water in there.

 

The vent hose was all cracked in the end. I cut the end off & stuck it back on with a tie. Pretty sure it was the offender.

Good advice! Thanks again!

 

Best I can measure a -234 O-ring may be a suitable replacement for the factory O-ring on the actuator cover.

 

Did you actually take yours off and measure it?
You're the only person I know that would do something like that.

Me? No.
I don't take anything apart unless it's broke.

 

No, I've had mine off to get a picture of the correct timing before though.

I have a spare one laying around that @DesertRatliff sent me, I use it for show and tell purposes.

 

Is that an actuator in your pocket...

 

No But I keep it handy in case a need to check something or a picture.

 

@Dm93 @TnShooter to the rescue once again. Yall are awesome

 

Sadly my fix was short lived. I took the cover off again to put on the gasket when I attempted to put the gear back in I couldn't seem to line it up properly. Anyways, it's 2wd, but I cannot engage 4wd! I'll post my voltage readouts tomorrow morning. I spent damn near 3 hours trying to match it up properly. Time for a beer!

 

I have a picture of where it needs to be in 2wd, leme see if I can find it.

 

This is where it should be in 2wd (gear turned fully counterclockwise).

 

Thanks, I'll check it this morn. What's the yellow paste all over the gear, lithium grease?

 

is this correct??

 

Whatever grease Toyota uses.

The angle is a bit different but it looks like it may need to be a tooth or 2 more clockwise. Also make sure the contacts are good, they look like they may be bent back a bit in the picture.

 

So, I'm right back where I started. I can put it in 4wd HI or LOW, take it out of LOW no prob, the min i try to put it back in 2wd it just blinks. I have to crawl under and manually turn to 2wd. Any ideas?

 

You said you can shift it easily by hand though?

 

Yessir, very smooth. It goes into, & out of, 4wd LOW electronically no prob too.

 

When it does this did you check if the transfer case is still in 4wd by jacking a front wheel off the ground and seeing if you can turn the front driveshaft?

 

I can feel it without have to jack up the front. When you do a tight turn...it's gripping! Trust me, it's in 4wd.

 

You have a picture of where is the actuator gear at when you take the cover off after this event?

Also a picture of your contact plate?