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I have issues with my hi or lo 4 wheel drive not engaging on my 2000 LN167R Hilux. The front wheels are definitely not turning when hi or lo 4 is being used. Does anyone have any suggestions on what the issue might be? I've ruled out that it isn't an issue with the hubs and I did replace the 4WD fuse just in case.

RAC and a local transmission place have said that it is something to do with the transfer case. What things should I check for to try and fix the issue myself?

Thanks for anyones assistance on this

Also can anyone please tell me what this plug is for?

Have you jacked the front up and turned the front tail shaft by hand to rule out the diff?

Yes mate, I've ruled out the diff and it's definitely the transfer case. Has anyone got a diagram of the transfer case and the motor?

On my old truck the motor on the back of the transfer rusted up inside. There's nothing technical to it. Just pulled it apart and cleaned the contacts up. If you can spin a spanner give it a shot.

Does the truck feel like its in low range whem in L4?

It does feel like it's in low range so I can rule out the gearbox since the gear ratios do change. Just missing the drive to the front drive shaft

is it SR5? check and replace all vacuum lines, your driver side shaft may not be engaged. that plug looks like the low range sensor that activates the 4wd when low range is selected.

I'm not sure if it is a SR5, I don't think it is anyway. That's interesting and I assume there's another plug for hi range?

I assumed it was sr5 as you mentioned 4wd fuse. Has it got a push button on the transfer stick?

under the right hand front gaurd there is a little blue ish kind of inline water filter at the end of the line for the airline that actuates the hubs, if its cracked or missing no 4x4, the givaway is that on the dash the green 4x4 light will be activated telling you its in 4x4 but it will not be cause the air line is breached,

to check this put it up on stands or houst and pinch the line the front should engage.

My old 2000 I just stuck a tech screw in the end of the line and bingo

Lets us know what it was.

Thanks for the suggestion guys! Well it looks like I could swap the transfer case over for a good second hand one that's working. I have the Hilux workshop manual and a mate that's willing to help do the swap out. Is there much involved swapping out a transfer case?

Ended up getting this fixed and I replaced the transfer case The 4wd light comes and it is engaging fine now.