4x4 problems, any ideas welcome!

Hi Everyone,

I am based in Malawi, Africa, for work and I have been driving Hilux Surfs (what the 4Runner is called here) since 2005, I am a big fan.

I currently drive a 1996, 3rd Gen Surf, Auto, KZN 185 (diesel engine, kz-te, 3.0L).

I have often used the info on here and decided it's time to join.

I have a transfer case/4x4 issue.

Mine is the version with the Multimode 4x4, where you press the button and get AWD, then manually select on the lever to shift to H4 (lock centre diff) etc.

Basically I lost drive when I engage 4x4 on the button.

So I put the truck on axle stands, got a friend to sit in and operate the system, and this is what I found out:

as the button is pressed in, for AWD, you hear the usual clunk, the 4x4 dash light display comes on, the front diff engages very briefly, and the front wheels start to spin. However after a couple of seconds they stop, and so do the rear wheels, so drive is lost to both.

Locking the centre diff with the lever (H4 position) restores drive, but only to the rear drivetrain.

As you disengage the button, there is a lot of metal on metal noise, and then rear wheel drive is restored.

Any ideas?

Anyone who maybe has a link to the repair manual for the 1996 kzn 185, in English?

My local Toyota dealer only seems to be able to access to the Japanese one.

They also have access to the 1996 US 4Runner Toyota manual, which is in English, but the 4x4 system seems different, more like the 2nd Gen, without the option of the lockable centre diff.

Thanks and all the best

 

Yes, that's kind of correct. The actuator next to the transfer case engages the front diff, so you then have AWD, whereby you can drive on tar in 4wd , a bit like some full time 4x4s like Subarus, I guess.

Then if you pull the lever into H4, that locks the centre diff.

 

Thanks for these links, I have a look in the next couple of days, much appreciated.

 

After discussions with my mechanic , we have realised we need the pages from the manual with the instructions for inspection of the transfer case , with diagrams etc. It's the multimode version with lockable centre diff, I think it came out in US in1999.

The local Toyota garage can only access them in Japanese .

Has anybody got a copy of the English version?

Many thanks

 

After discussions with my mechanic , we have realised we need the pages from the manual with the instructions for inspection of the transfer case , with diagrams etc. It's the multimode version with lockable centre diff, I think it came out in US in1999.

The local Toyota garage can only access them in Japanese .

Has anybody got a copy of the English version?

Many thanks