2008 Toyota Hilux D4D 4x4, +/- 160 000km - Diff Lock Problem

Uysster · Post by **Uysster** » Sun Feb 09, 2014 5:27 pm

Good day.

Seems like I've run into my first problems vir my hilux since owning it now 3 months.

We did a 4x4 trail today. Diff was initially working, but after some time when I wanted to engage it again I noticed it is not kicking in, since the red light indications just keeps flashing.

Where do I start looking and trpublrshooting?
Financial implications is a definate downer so I have to try and walk the DIY route.

Please, is there someone out there that can assist me with this - It's stressing me out now, since I'm afraid something seriously is broken and I cant afford repairs right now.

Thanks in advance for any help and assistance.

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Post by **Mud Dog** » Mon Feb 10, 2014 12:43 am

George, relax a bit before thinking big bucks repair .... those units don't just give mechanical hassles without serious abuse, other than the actuator getting bunged up with muck.

Firstly, you say it was working and then suddenly not ...... that might imply an electrical problem. Maybe one of the wires to the actuator motor got snagged on the trail somewhere. Start at the motor itself and check that the wires are all in place .... you could also unplug the socket and clean the contacts with some contact spray. Then try it again, but remember to do it slowly on grass / gravel and not a solid surface .... you will also need to move the vehicle in an arc (steering turned - not in a straight line) so that the differential works. Also remember that it will not engage in 2h or 4H (wired like that for safety reasons). It will only engage in 4L. Come to think of it, this alone may have been your problem.

If nothing above works, unplug and remove the unit, strip and clean, re-lube and re-fit. When refitting I think you have to insert your finger into the hole and manually engage the locker fork prior to fitting ... not 100% sure about this so perhaps someone can verify.

Good luck.

Mars67 · Post by **Mars67** » Mon Feb 10, 2014 6:54 am

I can confirm what Mud Dog says. Some time ago I thought that my diff lock also wasn't engaging anymore. I was in 4L but travelling in a straight line. It did not engage even after travelling several 100 meters in a straight line. (I was just checking to see if it works). Then I realised the two side shafts are turning at the same rate and started turning. The diff lock engaged immediately. It only works in 4L. When you are in a situation where you need the diff lock the instructions are to stop, engage the diff lock whilst stationary and then to release the clutch slowly.

Uysster · Post by **Uysster** » Mon Feb 10, 2014 8:27 am

Mud Dog wrote:George, relax a bit before thinking big bucks repair .... those units don't just give mechanical hassles without serious abuse, other than the actuator getting bunged up with muck.

Firstly, you say it was working and then suddenly not ...... that might imply an electrical problem. Maybe one of the wires to the actuator motor got snagged on the trail somewhere. Start at the motor itself and check that the wires are all in place .... you could also unplug the socket and clean the contacts with some contact spray. Then try it again, but remember to do it slowly on grass / gravel and not a solid surface .... you will also need to move the vehicle in an arc (steering turned - not in a straight line) so that the differential works. Also remember that it will not engage in 2h or 4H (wired like that for safety reasons). It will only engage in 4L. Come to think of it, this alone may have been your problem.

If nothing above works, unplug and remove the unit, strip and clean, re-lube and re-fit. When refitting I think you have to insert your finger into the hole and manually engage the locker fork prior to fitting ... not 100% sure about this so perhaps someone can verify.

Good luck.

Hey, "Mud Dog".

Thanks for the positive reinforcement.
My only logical theory currently is, electrical problem.

I am aware that the d/l will only engage in 4L. (No mods done to allow it otherwise.)

However, I will try it once more, by turning sharply to either side, so as to get different speeds on the two wheels, to see if the diff will then lock. (This is not always possible on a track / trail...)

If this still does not work, I'll have to start investigating further and deeper.

I'll post my findings / fixes here. Thanks.

Uysster · Post by **Uysster** » Mon Feb 10, 2014 2:44 pm

Waar toets ek vir watse voltages by die diff lock assembly?
Het contact spray ingespuit by die 2 connectors. Steeds niks.

Ek het bevestig, die d/l sluit defnitief glad nie!!!

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Uysster · Post by **Uysster** » Mon Feb 10, 2014 4:16 pm

Good day.

I require technical assistance please.
I am fairly good technically inclined, leaning more to the electrical and electronical side. Although I can help myself kind of.

From a mechanical point of view, I need stricter guidance.

The currenct vehicle in question is the standard, 2008 Toyota Hilux D4D SRX 4x4 with under 160 000km on the clock.

Here's the current problem;
While doing a 4x4 trail yesterday, I noticed some way into the trail that the diff-lock was not engaging anymore. (Though it was doing so earlier in the track.) No mods have been done and the diff can only lock in 4L.
When in 4L and stationary, depress the D/L button after which you can hear a relay click and the red illumination light starts to flash. The diff lock does not engage at all, even by making very sharp, slow turns to either side. The light keeps on flashing until the button is disengaged. (In the recent past, when the diff locked, it indicated so by illuminating the red light constantly.)

Here's what I have done / troubleshooted so far;
- I've tried to engage by standing still, engaging 4L and then engaging D/L, driving straight, driving with sharp turn to either side.

- I removed the protecting plate, removed both connectors, sprayed some contact spray into them, but to no avail.

- I took a multimeter and measured between all the plug points, after removing them, with ignition off AND with ignition on, after engaging 4L + D/L.
I do not ready any DC voltages between any points. (No sure if it should be like this or not.)

So, where do I start scratching next?

English OR Afrikaans responses are more than welcome! (A photo or 2 will also help.)

Masekind · Post by **Masekind** » Mon Feb 10, 2014 4:35 pm

Uysster wrote:Waar toets ek vir watse voltages by die diff lock assembly?
Het contact spray ingespuit by die 2 connectors. Steeds niks.

Ek het bevestig, die d/l sluit defnitief glad nie!!!

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Hoeveel draadeis op die VACUUM ACTUATOR plug?

Masekind · Post by **Masekind** » Mon Feb 10, 2014 4:37 pm

Kyk ook of die vacuum pyp nie uit getrek het nie

Uysster · Post by **Uysster** » Mon Feb 10, 2014 5:00 pm

Manne praat "afrikaans" asseblief...

Spot net so bietjie. Ek neem aan die actuator ding is die solenoid besigheid...

Na hom toe gaan een plug met 5 drade!
Daar is nog ñ tweede plug met net 2 drade, daar naby ook.

Dan kom daar ñ dukkerige pypie / draad ook uit die gedoente uit.

Uysster · Post by **Uysster** » Mon Feb 10, 2014 5:02 pm

Het probeer fotos oplaai, maar dit wil nie lekker job op die forum nie, en boonop is hul nog te groot ook.

Uysster · Post by **Uysster** » Mon Feb 10, 2014 6:56 pm

I've confirmed now that when I depress the d/l button the actuator is at least doing something. Whether or not its doing what its supposed to is maby yet to be confirmed?

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ChrisF · Post by **ChrisF** » Mon Feb 10, 2014 7:18 pm

Uyster PM my jou epos adres ...

Uysster · Post by **Uysster** » Mon Feb 10, 2014 7:41 pm

Lyk my ek het die verdomde culprit!

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Uysster · Post by **Uysster** » Mon Feb 10, 2014 7:44 pm

Kar opgejack ign aan 4L d/l aan, kan hoor die actuator werk! Met dl aan, kry ek nie eers die wielle gedraai nie. As dit af is kan ek die wielle gemaklik draai en dan draai beide in verskillende rigtings.

Bou toe sensor uit. Dit is so spring loaded meganisme. As ek dit heel indruk en met multimeter continuity gemeet, dan meet ek steeds niks nie.

Kan iemand bevestig asb, kan ek as ek als gelock het, met ñ draadjie die sensor plug se punte uit brug en kyk of die rooi lig permanent skyn?

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Post by **Mud Dog** » Mon Feb 10, 2014 8:13 pm

Kar opgejack ign aan 4L d/l aan, kan hoor die actuator werk! Met dl aan, kry ek nie eers die wielle gedraai nie. As dit af is kan ek die wielle gemaklik draai en dan draai beide in verskillende rigtings.

Dis hoe dit hoort te wees ... dit beteken dan dat die D/L eintlik werk, al wys dit nie so op die indicator nie.

Ek's nie seker nie want ek ken nie jou locker goed nie, maar ek vermoed dat die plug met die twee drade waarop jy g'n spanning kry nie, die indicator drade is. Probeer hul altwee teen die chassis / earth met 'n multimeter terwyl jy doen soos jy bo genoem het (ign aan 4L d/l aan). Een van hulle behoort voltage te hê, dink ek. Brug hulle uit en kyk wat maak die indicator .... as dit werk dan weet jy die sensor switch binne die actuator is kaput of sit vas. Ek's geneig om the dink hy sit net vas weens vuilis binne.

Uysster · Post by **Uysster** » Mon Feb 10, 2014 9:11 pm

Ok, die sensor is bietjie skoon gemaak en dit werk nou, maar ek sit steeds met dieselfde probleem.
Toe brug ek die sensor se drade op die connector uit en dit los nogsteeds nie my probleem op nie. Het weer confirm, die diff sluit defnitief!
Wie weet waarna toe en watae roete loop daardie sensor drade?

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Post by **Mud Dog** » Mon Feb 10, 2014 10:11 pm

Was daar wel spanning op een van die drade gewees?

Mars67 · Post by **Mars67** » Tue Feb 11, 2014 6:50 am

Goeie inligting sovêr dankie.

Uysster · Post by **Uysster** » Tue Feb 11, 2014 9:31 pm

Aai julle, ek sukkel nogsteeds.
Gaan die ding brand steek.

Het vandag nog soveel toetse en goed gedoen en verder gepeuter, etc.

Volgend een van my toetse blyk dit of die 4L switch dalk probleme maak, maar ek's nie seker watse een presies dit is nie.
Dit lyk of daar dire moet wees, en ek kan net by twee uitkom. Alhoewel die een so snaakse sensor is met ñ spring aan die binnekant, etc.
Die ander een is wel soortgelyke skakelaar soos op die agterste diff.

Het die diff lock 4x4 boksie ook getoets en daar was twee goed wat my gepla het... Een verwys na die 4L sensing skakelaar en die ander lyk of dit verwys na die diff sensing skakelaar.

Ek het vanaand weer iets snaaks opgelet wat vir my fishy lyk... met continuity meet ek ñ short op beide punte van die plug wat op die agterste diff se sensing skakelaar inplug. As die ignition af is, verdwyn die short, maar as die ignition aan is, ongeag of ek in 2H, 4H, 4L of D/L is, kry ek daai short.
As die motor idle, bly die short steeds daar...?
Kan iemand bevestig of dit so moet wees?

Ek weet nie meer nie, enige raad...
Ek sê julle op die uiteinde van die dag is dit net iets simpel!!! "Murphy's Law"!!!

Uysster · Post by **Uysster** » Tue Feb 11, 2014 9:44 pm

Mud Dog wrote:Was daar wel spanning op een van die drade gewees?

Niks nerens nie. Nie tussen die twee punte nie, en ook nie tussen ñ punt en grond nie.
Van wat ek kan "sien", moet daar niks wees nie, dit is net ñ kontak wat deur die diff geskakel word. Of dit negatief terug 4x4 ecu toe moet skakel weet ek nog nie.

Alhoewel, soos gesê, ek meet ñ short oor daai twee drade,, sodra die ign aan is...

Post by **Mud Dog** » Tue Feb 11, 2014 9:50 pm

As ek net 'n klip in die bos mag gooi ..... miskien het dit iets te doen met " a floating earth" .... die SFA's het dit, maar ek weet nie of die Vigo ook van 'n 'floating earth' gebruik maak. Miskien kan dit die rede wees dat jy continuity kry pleks van daar 'n short te wees?

Eish! Ek wens ek was nou 'n autolek sodat ek jou kon reghelp.

Uysster · Post by **Uysster** » Tue Feb 11, 2014 9:53 pm

Kom ons kyk wat reply die ander...

MCHILUX · Post by **MCHILUX** » Wed Feb 12, 2014 7:34 am

Hi George
Ruil die reverse ligte switch en die een op die difflock om en kyk wat maak hy. Die switches is dieselfde maar reverse werk hy net open close op die diff lock het weerstand ook n invloed.Dit het al n paar keer vir my die probleem opgelos.

Uysster · Post by **Uysster** » Wed Feb 12, 2014 10:35 am

Ek't jou nou net gepm, voor ek na my post gekom het, skuus tog man.

MCHILUX, kan jy my bietjie direct - Waar gaan haal ek die reverse ligte se skakelaar uit - Ek doen dit met graagte!

Uysster · Post by **Uysster** » Wed Feb 12, 2014 10:36 am

Vir al wat ek weet het ek hom seker klaar gisteraand uitgebou om skoon te maak en te toets, sonder dat ek geweet het dis die reverse ligte se switch...

MCHILUX · Post by **MCHILUX** » Wed Feb 12, 2014 1:04 pm

Die twee skakelaars is 1:Difflock switch op diff lock housing plug met twee drade
2:Reverse light switch op kant van ratkas aan exhaust kant ook twee drade op plug
Altwee skakelaars se plastiese dele is grys

Uysster · Post by **Uysster** » Wed Feb 12, 2014 1:17 pm

Ek maak nou net gou ñ draai by Toyota om net eers uit te vind wat kos die twee skakelaars...

Die reverse lig een kos net so onder die N$ / R 400 en die een op die diff kos net so onder die N$ / R 1700

Ek dink die persoon wat die pryse sit ek uitmaak, rook verskriklike gevaarlike goed!

Uysster · Post by **Uysster** » Wed Feb 12, 2014 7:13 pm

Ek kan confirm, dit is beslus nie die switch nie!
Het die reverse lig switch geruil met die diff lock sensing switch, selfde probleem.

(Die short wat ek gister gemeet het op die diff lock sensing switch se plug is vandag weer weg...)

Ek is te bang om te vra, maar wat is die moontlikheid dat die probleem in die loom is wat bo oor die brandstof tenk loop?

Mens het ñ blerrie graad nodig om Toyota se elektriese drawings te kan lees!
Waar by een van die twee 4wd ecu's kan ek toets en meet of daai senser op die agterste diff well voor uitkom of nie?

Post by **Mud Dog** » Wed Feb 12, 2014 8:11 pm

Maybe something here can help you?

Uysster · Post by **Uysster** » Wed Feb 12, 2014 10:38 pm

Raai wat... ek gee vir eers moed op.
Die diff lock sensing switch werk, die 4WD switch werk. Die 4L switch werk.

Die difflock engage fisies - maar die verdomde rooi liggie bly net flikker.

Al wat ek dink wat oorbly is die cluster... daar wil ek nir graag krap nie.

Enige raad en opinies is steeds welkom.

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Jaws · Post by **Jaws** » Thu Feb 13, 2014 5:19 am

Uysster hoekom pla die liggie jou so? Myne flikker van die dag wat ek my bakkie gekoop het , so ek het nog Altyd gedink dit is Maar hoe hy werk. Eers laas jaar uitgevind die liggie is veronderstel om aan te Bly.

My diflock skop in elke keer as dit nodig het , nog nooit ooit 'n probleem gewees nie. Ek weet van nog twee ander waar die diflock liggie flikker en ons almal se diff locks werk

Uysster · Post by **Uysster** » Thu Feb 13, 2014 10:11 am

Want... Dit is nie reg so nie - Dit het gewerk nog die naweek, en toe skielik nie - Ek lê wakker in die aande oor dit!

HAHAHA!

Uysster · Post by **Uysster** » Thu Mar 13, 2014 9:58 pm

:-|

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Uysster · Post by **Uysster** » Tue Apr 01, 2014 7:10 am

.

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Masekind · Post by **Masekind** » Tue Apr 01, 2014 5:24 pm

Het jy al iets reg gekry?

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Uysster · Post by **Uysster** » Mon Apr 07, 2014 8:01 pm

Nee.
Maar ek moet pleit, ek het ook nog nie verder gekrap nie.

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Uysster · Post by **Uysster** » Sun Jun 25, 2017 8:10 pm

Terloops...
Dit was ñ draadjie wat stukkend was wat die sein moes gee dat die diff wel gesluit is.
Ek self het dit nie herstel nie maar ñ Toyota agent. Ek is nie 100% seker nie maar ek dink hierdie draadjie was stukkend tussen die brandstof tenk en die body. So tenk moes uit.

Mars · Post by **Mars** » Mon Jun 26, 2017 6:33 am

Goed om te weet. Ek wonder nogal oor die draadijie by die brandstof tenk want die drade van die ratkas loop nie een daardie kan toe nie maar op en vorentoe. Ten minste bly dit is reg.

Uysster · Post by **Uysster** » Mon Jun 26, 2017 8:39 am

Ek mag onbewustelik verkeerd wees. Dalk het hul die boodskap verkeerd oorgedra aan my doerrie tyd.