Trouble-shooting
your ADD system
Trouble-shooting
is often a processes of elimination, test parts, figure out what works
then move on the the next. There are more than 50 individual parts that
make up the ADD system and creating a flow chart that includes every possible
solution is beyond the scope of the article. For trouble shooting the electrical
and vacuum sections of the ADD system you will need the Toyota factory
service manual and excellent trouble shooting skills.
The most common problem
is damage, deterioration, or mis-routed vacuum hoses. To ensure the vacuum
lines are routed properly, they are marked with either a blue or brown
tracer stripe on the hoses. These hoses should match up with the corresponding
VSV under the hood. In some cases during engine or collision repairs, these
hoses get routed incorrectly or left disconnected altogether.
When the transfer
case gear shift is shifted into 4WD, the ADD system is actuated by the
operation of the ADD solenoids located under the hood on the passenger
side wheelwell. The solenoids are supplied voltage from the ADD relay which
depending on the type of transmission the vehicle is equipped with, has
it's ground completed by both a Transfer Position Switch and a Transfer
Pressure Switch (V6 with automatic transmissions), or a Transfer Indicator
Switch (4cyl.-- manual trans.). These solenoids control the vacuum signals
to the ADD actuator which is mounted on the front axle. This actuator engages
a sleeve inside the differential via an "intermediate shaft" which is attached
to the driver's-side side gear shaft and clutch mechanism.
If the ADD system
does not properly engage the front drive mechanism, the first items to
check are the vacuum supply hoses. First, look under the hood and locate
the ADD solenoids. Ensure that the vacuum hoses are connected to the solenoids
or vacuum switching valves (VSV) as they are commonly called by Toyota.
Next, look at the hoses at both the differential and vacuum reservoir located
in the R/F wheelwell. Make sure all hoses are connected and not torn, cracked,
or otherwise in poor condition. Once the system is engaged or disengaged
from 4WD, it will stay in that position. Basically, if the system is not
functioning, the vehicle can be placed in either 2 or 4 wheel drive manually
with a vacuum source for testing. If you plan to leave the ADD system disconnected
you will need to apply vacume from the engine to make sure the front end
does not unlock.
The ADD relay can
be inspected for operation as well. This relay is located under the instrument
panel on the passenger side of the steering column. Check for continuity
between terminals 2 & 6 and 1 & 3 (see diagram). Upon applying
12 volts continuity between terminals 1 & 4. Replace the ADD relay
if it fails the above tests. The VSVs or ADD solenoids can be inspected
as well.This is another resistance check so a DVOM is needed here as well.
Disconnect the electrical connector from the VSV and check to see if the
resistance is between 38-45ohms. Replace the VSV if the resistance doesn't
meet this specification. A function check of the VSVs will show if the
valves are working internally. By applying battery voltage to the connector
and blowing air into the lower hose fitting, air should come out of the
top fitting and not the lower "filter" on the VSV. Once battery voltage
is removed, air should pass through the filter and not the upper hose fitting.
A final check can be made of the ADD indicator switch which is located
on the ADD actuator itself. This switch acts like a brake light switch.
Remove the switch from the actuator. Depress the switch button and check
for continuity between the terminals of the connector. If there is no continuity,
replace the switch. Depending on the type of wheeling you use your ADD
truck for, you may decide to retain the ADD system or eliminate it all
together.
Testing the engagement
of the ADD sleeve is relatively easy requiring only a vacuum source. First
disconnect the two vacuum hoses from the ADD actuator unit and put the
truck in 2WD on level ground. If your truck is equipped with manual hubs,
lock the hubs for this test.
Testing for 2WD:
Put a hand vacuum pump on the drivers side and apply 15 lbs of vacuum.
This will pull the actuator into the 2WD position. At this time you should
be able to turn the front drive shaft by hand with out the front axle shafts
turning. The actuator should be able to hold the vacuum without leaking.
Testing for 4WD:
Now place the hand vacuum on the passenger side of the actuator and apply
15 lbs of vacuum. The sleeve should slide into the locked 4WD position.
you should no longer be able to turn the front drive shaft (by hand) as
the add unit is now engaged. The actuator should be able to hold the vacuum
without leaking. |