Cheap A.D.D fix. Flashing 4wd light/water issue please read!

Cheap A.D.D fix. Flashing 4wd light/water issue please read!

Postby justos on Mon, 11 Mar 2013 11:22 +0000

***EDIT -Not on this forum much anymore (sold the lux) so sorry if i don't reply.*** i get PMs still

This thread is about how to FIX your A.D.D, not replace but fix, very cheap!

ATT mods: I thought I would start a new thread to get as much attention from everyone as possible. Even if you don’t have the flashing light it’s something to look out for. Open yours up and check, just one more thing to add to the list of checking before a long trip.

This method will cost about $25 depending what you have at home.

Issue: Flashing 4wd light on dash, sleave in front diff not engaging front drive shafts.

Reason: Most likely water in your A.D.D (automatic disconnecting differential aka differential vacuum actuator assembly in the repair manual). This is the part on the front diff of the SR5’s that disconnects the drive shafts from the diff centre. Ps it’s not a vacuum it has a breather hose and that’s it, only god knows why Toyota does these things!

Known repair method: Replace the whole actuator which is $630ish from Toyota and about $500ish from the wreckers.

Tools needed:

1. The basics screw drivers, pliers, hammer, and so on.
2. Soldering iron (optional)
3. Dremel or similar.. u can manage without one but jeez they make work easier!
4. Air compressor, not a must but does help.
5. Cleaning solvent. Prepsol/ wax and grease/ alcohol, whatever.

Items needed:
1. New motor RE-385 see below for link, $16 delivered from Sydney
2. Conductive grease, $10 from Jaycar
3. Gasket paste/ seal, supercheap $not sure 5-15?
Image[/url]
Conductive grease - Jaycar

Ok so as you may have gathered I had the flashing light, so I jumped on this thread http://www.newhilux.net/forum/viewtopic.php?f=12&t=15032, which told me I had water in my A.D.D. So up went the car, opened my A.D.D and low and behold rust, corrosion, and water. Great…. There goes $600 odd dollars. No chance was I spending that money on it!
Image[/url]
Corroded!
Image[/url]

The only major issue with mine was the motor was rusted to sh!t house (and judging everyone else’s pictures they had the same issue). So why replace the whole thing for one small part?

NOTE: I did not take the whole A.D.D off the diff. If you do this you will have to drain the diff and for no reason. All I did was undo the 5 screws that hold the plastic housing onto the A.D.D

Also note I’ve got the Ultimate suspension smart lift. So I’m not sure if you need to drop your diff to get access to it. If someone can confirm that, that would be great.

After 3 days of researching for an exact replacement at Jaycar and other stores I had no luck. Then I finally found one on the net. I wasn’t sure if it had the right torque or not but $16 delivered from Sydney was a small price to pay. Here’s the link and details of the new motor.

Motor link: http://australia.rs-online.com/web/p/dc-motors/2389737/?searchTerm=238-9737&relevancy-data=636F3D3126696E3D4931384E525353746F636B4E756D6265724D504E266C753D656E266D6D3D6D61746368616C6C26706D3D5E5C647B337D5B5C732D2F255C2E2C5D5C647B332C347D2426706F3D313426736E3D592673743D52535F53544F434B5F4E554D424552267573743D3233382D393733372677633D4E4F4E4526
For people not in Australia, you can check out RS components, there in the UK. Or try and find a supplier near you.

Motor Specs: http://docs-asia.electrocomponents.com/webdocs/0032/0900766b800320ab.pdf


2 days later the motor came. Pulled the old A.D.D apart and gave whole housing a detailed cleaning. I used a wire wheel on the dremel to clean the alloy part of the housing (diff part) and prepsol (wax n grease) for the plastic part. I also used the dremel to clean all the parts inside the plastic house to remove as much corrosion as possible. Then I gave it all a good blow out with the compressor.
Image[/url]
All clean (this is where dremel makes life easier… best tool ever!)

Now there’s a small coupling piece on the shaft off the old motor that needed to be removed and put on the new one… it needs force. I put my old motor in the vice and put two flat head screwies on either side and pried the piece off.
Image[/url]

I had to cut the tip off the shaft on the new motor to make it fit. Cut the shaft down to 6.25mm…don't cut 6.25mm off! cut it down too. Ref picture. DON’T stress if you’re a bit off, it won’t fit if it’s too long though. Again I used the cutting disc on the dremel. Now, the small coupling part off the old motor needs to be stuck on the new one with Loctite. It took me all night to realise that. I had it all back together and couldn’t realise why the motor just kept spinning. Just be careful not to get Loctite in the motor bearing (the part that the shaft spins on) or it could lock up.
Image[/url]
New length, already cut down.

Now you can solder the new motor, I did, but it does work without it (just not sure how long it will last).
That’s basically it. Put it all back together; use the conductive grease on the metal strips in the housing (black goo). I also used gasket paste (brown goo) on the housing just to make it more water tight, you’ll see when you open it that the gasket that’s on there is sh!t house!. Don’t forget to put the breather house back on. (I’ve now extended mine also). You can also clean the terminals on the plug and housing, because why not lol.
Image[/url]

Here are a few extra pictures, always helps.
Image[/url]
I glued (Loctite) the coupling a bit too far out and it was hitting the plastic housing. I just pulled out the dremel again and took some plastic off where it was hitting. U can use a small file if you have this issue.

Image[/url]
Motor soldered.

I hope I’ve mentioned everything, don’t hesitate to ask, comment, or debate im all ears.
Last edited by justos on Tue, 01 Aug 2017 6:57 +0000, edited 7 times in total.
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby justos on Mon, 11 Mar 2013 11:30 +0000

Ps make sure u connect the plug back in fully (hear the click)

Also we run the same A.D.D as the FJ cruiser, same part number.

So if anyone is on the FJ forums maybe throw this there way? although the guys in the states pay $260 for a whole new A.D.D (toyota Aust love rippin us off!)
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby 10 luxxxx on Mon, 11 Mar 2013 11:45 +0000

Great info mate thanks for taking the time.
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby justos on Mon, 11 Mar 2013 12:16 +0000

no problems. Glad i can give something back :D cheers
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby deffer64 on Mon, 11 Mar 2013 4:56 +0000

Thanks heaps for the info atualy got the old one back from toyota even tho they warrantied it so will get a motor and fix it for a spare or if i come across somebody on the tracks that needs it . :) :) :)
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby jakelux on Mon, 11 Mar 2013 5:12 +0000

Thats great mate very thorough!! I may just pop the lid on mine and have a look, Have had extended breather on for years but still be worth a look and if is all good i will put some gasket seal around the housing before it goes back on.. :D
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby Steve9R on Mon, 11 Mar 2013 5:14 +0000

well done.. definitely something I'd look at as well.. even if just to check out how much water etc was in there.. (although i do have the extended breather on mine)..

Steve
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby mow44u on Mon, 11 Mar 2013 5:26 +0000

Where was this 6 months ago???? Good on you for having a crack at it.

Better late than never, but I still have the old one to play with if i feel like having a spare.

With my old ADD unit, I powered the motor directly and had it spinning, so i figured that my problem was elsewhere in the unit. But i dont see where else as there's not much more to it.....

Like you, I also added a heap of extra slilcon to the outside of the plasic case. That tiny rubber gasket may be another source of water ingress if you like to play in puddles.

As you have stated, it is Not Vacuum operated. The previous IFS hilux's and Surf's ones are and many people assume that this one it as well. But we cas see that it is all electric
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby justos on Mon, 11 Mar 2013 5:36 +0000

jakelux wrote:will put some gasket seal around the housing before it goes back on.. :D


Good idea. Again some more cheap insurance :D

Mow44u, hate giving people bad news :( . my motor still worked aswell when i connected it up to direct power, just didn't want to take the risk, how ever i came very close to using it again after day 3 into the research :lol:. So not sure if it was a connection problem or what. i can only think of either the large gear in the housing not in the correct position or the plug not connecting properly, thats why i cleaned the little terminals in the plug. Also the pins on that large gear may not have been connecting to the metal strips inbuilt into the housing. Duno. but if you have a spare it may be worth fixing it and selling it on ebay? try and get some money back. (if you get a hilux manual you can test the A.D.D not on the vehicle using the wiring diagram, just put power into the correct spots :lol:


again cheers guys glad i could help.
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby mow44u on Mon, 11 Mar 2013 5:42 +0000

Thats good news.

It means I had the same problem as you and if i replace the motor it might work and ill have a working spare.
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby bkstravel on Mon, 11 Mar 2013 6:09 +0000

top stuff good write up mate..
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby justos on Tue, 12 Mar 2013 6:06 +0000

bkstravel wrote:top stuff good write up mate..


Cheers :)

mow44u wrote:Thats good news.

It means I had the same problem as you and if i replace the motor it might work and ill have a working spare.


Let me know how you go, ill be glad to help
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby kickinback on Sun, 17 Mar 2013 6:44 +0000

Good thread mate. Thanks for sharing.
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby grantos on Mon, 01 Jul 2013 9:29 +0000

Great article ! my 07 hilux is doing the same,will definatly check out the a.d.d. unit for water and extend the breather.
Thanks for the info :)
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby Blackie2008 on Wed, 14 Aug 2013 9:43 +0000

Same here, this is on my to do list. Thanks for the write up! 8-)
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Build thread: http://www.newhilux.net/phpbb/viewtopic ... 41&t=15092
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Cheap A.D.D fix. Flashing 4wd light/water issue please read!

Postby Blackie2008 on Fri, 30 Aug 2013 10:51 +0000

Mine wasn't too bad fortunately. Only a half a cup or so of water came out when I cracked the plastic cover off.
Image
Image
I've put it back together not being sure of where the gear needed to be but since the motor just runs until it reached its limits I thought it would figure it out. Tested the motor with 12v and its running fine.
Problem though....

My 4x4 keeps flashing now, regardless of where the selector leaver is positioned. 2H 4H 4L.
Any ideas?
Dan.

08' SR5 Dual Cab, Manual, Prado brake upgrade, 33" KM2's, DMS MR Rekon Stage II, MMKD, Stage 2 GTurbo, HPD FMIC, NPC Clutch, 360 UHD Gearbox...

Built, not bought

Build thread: http://www.newhilux.net/phpbb/viewtopic ... 41&t=15092
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby Blackie2008 on Fri, 30 Aug 2013 8:15 +0000

Don't worry, I fixed it. Note to future readers, make sure the large round gears keyway is correctly engaged in the actuating arm. It makes the world of difference.
Also, don't look to the factory workshop manual for advice. All it'll tell you is that this item is unable to be disassembled. Of course we know better though ;)
Dan.

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Build thread: http://www.newhilux.net/phpbb/viewtopic ... 41&t=15092
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby Marshwa on Wed, 26 Mar 2014 4:23 +0000

Hey guys, I had some dramas a while ago with not 4wd not working and my 4wd light not coming on. I took the lux into Toyota and they told me the add unit was buggered and I would need to pay $900 for a new one. I since found this thread and gave it a crack.

My 4wd is now working as far as I can tell (dirt road launches and 4wdriving) but my light still won't come on untill randomly the other day while in 2wd it started flashing. I figured I must have fixed the add unit since 4wd is engaging so but the bullet and took it back into Toyota to see if there was another reason the light wouldn't come on and then started flashing. They checked the ecu but tell me the add unit is still f$@#&% and while the 4wd is engaging it is not engaging properly.

Just after any idea of something I could have done wrong or other things to check myself before I bite the bullet and pay Toyota $1250 to swap the unit. I just can't for the life of me see what other electrics could be wrong with the unit?? Toyota tell me the black boxes on the front of the diff (what we're calling the add unit) come precalibrated from Toyota and cannot be pulled apart?!?

Any thoughts and ideas would be greatly appreciated guys, having a lot of trouble justifying so much money for something that doesn't look that complicated and now seems to be working as far as I can tell?

Cheers,

Max
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby packeteer on Wed, 26 Mar 2014 6:30 +0000

see if you can get one from a wrecker and do the swap yourself
2011 Dual Cab SR5 D4D manual.
build thread
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Re: Cheap A.D.D fix. Flashing 4wd light/water issue please r

Postby fgk228 on Wed, 26 Mar 2014 7:45 +0000

That electric motor looks like a standard Johnson 540 motor available at most hobby shops. They are around $20. They are used in just about every 12v application.

http://www.ebay.com.au/itm/Tamiya-53689 ... 2ecf50d82a
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