Outer Limits 4x4 Board

Hi everyone

I cant figure out how to get the motor on my Surf transfer case to work (no wiring), and am looking at getting a mechanical hilux transfer.

What are the differences, is there a particular model I should look for? I have been informed that the input is different between the hilux/4runner and surf, is this the case or are they inconsistantly different?

Thanks heaps

Don't know much bout 4Runner transfers, but thought they were same/similar to Surf.
What type of transfer did you have before ??

Do you have "push button" activation on the stubby stick for 4WD ??
If you do, the wiring is there you just need to find it and plug it in (right at the end of the loom).
If not maybe you had a gear driven transfer instead of the usual chain driven one.

auto ? , petrol ?, year ???????

sorry i thought that was in my sig, ill try again.

Its a 91 Surf, has a 1UZ with lexus auto and standard push button surf transfer

when the motor was put in they pulled out all the 4wd wiring and i cant find a way to get the motor to work properly, even with the diagrams, short of wiring the whole thing up again, which im not really keen to do.

need it fixed, really hanging out to take this thing out!

There is supposed to be a 4wd box/computer in front of the gear stick under the radio behind the dash. This is where the wiring would start from.

I believe you should be able to "hot wire" it from the push button on the 4wd stick direct to the motor on the back of the transfer, have not tried it myself so have a go at your own risk.
You won't get the green 4wd light on the dash but should engage the transfer so you get 4wd, and moving the 4wd lever to get low range.

OH, do you still have the ADD on the front IFS diff ?
If you do then you will also require FWH's and to leave the ADD engaged somehow all the time (swap the vacuum lines to the VSV's is 1 way) or you still won't get drive to the wheels.

thanks for your reply Dougster.

I have the computer, but none of the wiring exits the cab. It terminates behind the dash i think.

i thought about just wiring something to run the motor, but ideally should utalise the limit switches, without it can cause damage to the motor, and I want it to be reliable, im sure if it did fail it would be on the rough end of a track.

does have ADD but that was easy fixed by running a 3 position switch to the solanoids to turn one on/one off and vice versa. the diff is out to fit the lokka, so will probably do the hose clamp mod anyway, for reliabilities sake.

have already fitted FWH

ive seen on another forum that an adapter is needed to change the transfers, but have also heard that they are the same apart from the input shaft.

Have you tried going to the wreckers and getting the transferr harness which plugs into the plugs in the lefthand front kick panel and all should be good I can't imagine that they stripped any further back than this since the computer ect is still there

yeah you might be right russ. this way i assume that I will need the sensors on the front diff connected. that should be easy enough.

I was thinking that the transfer would be a more reliable option, but might not be as easy as bolting the new one on by the sound of it.

multimeter time again

Just get a harness from the wreckers strip it down leaving the transfer case wires and I left the temp sensor wire for the gauge in the dash as well the ADD wires come from the left hand front gaurd for the sensors so grab these wires as well while you are at the wreckers fit them all and should be ok if not you may need to pull your transferr motor off and free up the rod that activates 4wd as these some times have a habit of seizing up due to dirt and mud ect

there might also be some wiring diagrams in here
http://www.toyotasurf.asn.au/techsite/downloads.htm

also if you send me your email I can email another lot of manuals and wiring diagrams I have

ok have been looking around a bit to see what i do have to connect and what i can leave out.

according to this http://www.4x4wire.com/toyota/tech/add/ i can leave the ADD indicator switch off, and dont need any wiring to the VSVs. (will have the diff perminantly in drive position)

i would also like to be able to use low range 2wd for reversing trailers and i have read that the way to do it is to disconnect one of the plugs on the transfer. is this the transfer indicator switch (on the transfer motor) or the transfer L4 position switch (top LHS of transfer)?

i am using this diagram

It is the top left hand side of transferr as I have mine disconected also I only have 1 plug up there but some have 2 I think if you have 2 it is the front one and if that don't work try the back one lol

I had an hour or so to have a look at the wiring. thought that it was all looking good and I should be able to get it sorted.

no such luck. none of the wiring matches up with the diagram I have been trying to use. I have checked against the add relay, the wiring is not matching the pin outs provided.

this diagram doesnt seem to match up either.


now in a bit of a pickle. might have to test drive a surf for a couple of hours...

I went to the wreckers and traced the wires and cut off the motor plug and the plug for the transfer indicator switch (which didnt seem to make a difference). luckily the motor wiring colours and my diagrams matched, so i wired it up. The motor now runs for a second and the tailshaft cannot be turned (no front diff atm) and disengages when the switch is pressed again, so im pretty happy so far.

There is no 4wd light tho, and the motor is the only thing wired up, hopefully it proves to last. Cant wait to test it!

To check to see if the light on the dash works, link the 2 wires going to the front diff (simulates the ADD engaging), then try the button.

BTW, there are 2 electrical plugs to the front diff, 1 is for the ADD and 1 is for diff temp (if it gets too hot it disconnects the front, never heard of it happening tho).

the light works, i found the pin for it on the 4wd ecu plug, just need to find one to hook it up to.

there will be nothing going to the front diff, will do the hose clamp mod.