E-Locker Woes

[Kryptoroxx]

Trying to sort through all of this and I think it might be worth making a thread about as a step by step check process. Props to Sean0rz for saying it suggesting I bench test my e-locker before it was under the truck and another set of props and thanks for making and testing the harness to my e-locker so that I can narrow down what I have to test and what I don't. So lets start with what I checked first.

I checked my wiring as it's the most simple of the problems. My harness is set to work off of a single switch where a solid positive causes the locker to lock and the lack of a positive causes it to unlock. As to the rest of the harness's internal workings Sean is the man. He says it works so I'm going with that until proven wrong. So in my case I have all the wires/pins correctly and they are showing good circuits when tested with my circuit tester. Even my RR Diff lock is working on my dash when I apply a ground to the circuit.

After double checking connections I tried the locker again.....no dice. So now I turned to Google who showed me some horrific pics of e-lockers actuators gone wrong. I provided the link for what e-locker guts are not supposed to look like as well as how to rebuild one.

http://www.pirate4x4.com/forum/toyota-truck-4runner/698966-e-locker-actuator-rebuild.html

Here are the pics of mine.

http://imagizer.imageshack.us/v2/800x600q90/539/TD40r6.jpg (https://imageshack.com/i/ezTD40r6j)
http://imagizer.imageshack.us/v2/800x600q90/912/zuzomn.jpg (https://imageshack.com/i/pczuzomnj)
http://imagizer.imageshack.us/v2/800x600q90/633/dbdRmV.jpg (https://imageshack.com/i/hldbdRmVj)
http://imagizer.imageshack.us/v2/800x600q90/904/abzZKT.jpg (https://imageshack.com/i/p4abzZKTj)

If you're thinking....man this thing is brand new....you're with me. So now I'm scratching my head but it's late and my brain is tired. I am going to check wires and connections on the elocker tomorrow but the motor shows evidence of turning in the past so I'm left shrugging my shoulders on this one. Any more ideas are definitely appreciated.

Trying to get this sorted before this weekend. I have two days to get my diffs dropped and re-installed on a lift before the bill starts to hurt at the hobby shop. I figure I can do the rear in a day and the front in less than a day. I have all the seals, crush washers, etc for doing this one. Hell I could rebuild the axle but I'm waiting till I do the disc brakes just because I want the whole axle tube bare for that process.

[BattleWagonActual]

Hey man, I'll be back either Thursday or Friday. You can hook it up to mine and see if it works on that one if you haven't figured it out by then.


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[Seanz0rz]

That's a great idea. I really hope it's not a goof on my part!

[YotaFun]

That locker looks to be in perfect working order.
Double check the wiring, it should be good though, but maybe something got crossed by accident?
I've done it before where I was sure I had the wires done right and wouldn't you know it I had two crossed...

[Kryptoroxx]

Hey man, I'll be back either Thursday or Friday. You can hook it up to mine and see if it works on that one if you haven't figured it out by then.


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Lol dude your garage is destroyed! I was trying to get those monstaliner chips because a gunner wanted me to paint his rocker panels in monstaliner. He liked my tan though so it's all good.


That is an awesome idea though. Makes things much easier.

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[BattleWagonActual]

Yeah, I know I had most of everything boxed up until the command decided to tell me the night prior that I was leaving for the field 3 days early. I only had a couple of hours to do laundry and pack for the month. Needless to say rather than go through my gear in a neat fashion I just dumped it out to find stuff.


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[Kryptoroxx]

I took a second look at the wiring on the elocker and I agree with yotafun. That thing is in perfect working order. I will wait till Thurs or Fri and we will test the other elocker on it. That does two things. Fresh second set of eyes and provides a second elocker to test off of. We can go from there.

Hopefully I will have a paint job done on Fri or Sat for the gunner and on the outside chance that it is the harness I am perfectly willing to drive down to see you Seanz0rz.

If that ends up being the case would you mind helping me with the retrofit? I have the bits needed and I am sure I can do it but having someone there who has done it is always reassuring.

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[Kryptoroxx]

Ahhhh....just thought of this. What if the position sensor is out? No way to really test it but the motor wouldn't even engage if it was bad.

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[Seanz0rz]

Correct! That's what I was thinking when I was doing a driveway alignment a few mins ago.

[Kryptoroxx]

Its a pretty cheap part. According to pirate 4x4 its a reverse sensor off the w56. I will dig around for the exact reference I had. I remember 25 bucks as being the cost though.

stamped and snail mailed

[Kryptoroxx]

We tried the other elocker tonight with no luck so I'm going to check out my wiring again to double check. Everything seems to be in order but I did notice that when I engage the switch for the elocker that one of the lights for the other switches comes on so I might have to check my community ground on the switch panel to ensure there aren't any wires grounding out.

Does anyone have a part number for the w56 reverse light switch? Seems like everyone that had a bad sensor knows the price but I haven't seen a single part number to go off of.

The next step will be checking out the harness assembly as I don't see two elockers failing on the same thing. It seems that the position switch failure is rare enough as it is. Sean we can meet up somewhere to accomplish this. I was searching through on google and I think it's safe to say the wiring is a bit beyond my current talent level.

[Seanz0rz]

I would start by bypassing your wiring and giving the box a ground and 2 hots in the appropriate places. Double check your fuses. I'll be of more help tomorrow morning.

[Kryptoroxx]

I would start by bypassing your wiring and giving the box a ground and 2 hots in the appropriate places. Double check your fuses. I'll be of more help tomorrow morning.

Sounds good. After I work out I will rig a temporary setup.

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[Seanz0rz]

Here goes.

Remove the 4 pin harness from the box

Check continuity between where the white wire comes in (should be the pin closest to the edge, but double check) and the white/black wire on the end of the elocker plug (either plug should work for this, test both to be sure). If you don't have continuity, or a very large resistance, then something is wrong with the ground.

Use some scrap wire to connect the ground to ground (at the battery) and the yellow and orange to positive 12V. Leave the Blue wire alone for now. The locker should cycle locked until you remove yellow from 12v. To cycle it unlocked, the orange still needs to have power.

I can't find my schematic, but it is functionally similar to this:
http://www.4x4wire.com/toyota/tech/electric_locker/elec_locker_wiring.GIF
(Thanks www.4x4wire.com)

With the exception being a relay in place of the switch on the right hand side, enabling control with a simple on/off.

[Seanz0rz]

here is a quick edit that is more in line with what you have.

https://farm6.staticflickr.com/5576/15082699842_7e2590fa7b_b.jpg (https://flic.kr/p/oYNMc1)elec_locker_wiring (https://flic.kr/p/oYNMc1)

[Kryptoroxx]

Hey thanks Sean! I will be getting to this tomorrow morning. In-laws showed back up yesterday and market was this morning so I got away with cleaning up the disaster that is my garage and getting a little more ready for moving but no testing. I might be able to squeeze it in tonight but I would much rather do this in the light of morning.

[Kryptoroxx]

Well there's good news and bad news and the best news. The best news is....it isn't the locker, both of them are fully functional and work flawlessly, the good news is it isn't the harness either so Sean thank you for the support and ideas to help me along, and the bad news is I have no freakin clue where my wiring is wrong lol.

Going to start by introducing my switch into the wiring. At least then I can rule that out if it works. I'm thinking one of two errors occurred. Either the 12v and the Acc are switched up or somehow the ground is messed up? I know both of those errors would be easy to make and would cause everything not to work at all.

After those ideas I feel like the dog on duckhunt when you got skunked.

[Seanz0rz]

What switch are you using? Link? Where are you grounding to? Where are you drawing power from?

[Kryptoroxx]

I am using a spst contura v from otrattw.net

Ground I used was the metal frame of the steering wheel and the acc is the cigarette lighter. Fused goes straight to my aux box.

[Seanz0rz]

Check if the acc gives you power. Could be a blown fuse there

[Kryptoroxx]

All my lights are on the same line and they work. I need to go out and test the switch in the morning. It was too dark to do it tonight

[Seanz0rz]

OK, Test the switch, and if it has a light, make sure you are on the correct terminals.

[Kryptoroxx]

I was and the switch is good and the harness is not switched up either. That narrows it down to the ground. Not 100% on this but probably using the same ground for the switch as the box might cause confusion? I'm going to move the ground to the firewall and see if this helps.

This will be done tomorrow. Currently I have a cold that BattleWagon gave me (hopefully one of those 24hr things) and my entire body aches. It doesn't help that I went on a quick 2 mile run this morning before I realized that I'm running a little warm. I had just enough energy to do the jump terminals and test it out. Sorry for the slow progress everyone.

[Seanz0rz]

I use the screw for the kick panel bracket (the yellow zinc chromate one) as a ground. Never given me a problem. Using the same ground shouldn't hurt, but I worry that maybe the ground isn't good enough and that is giving you problems.

[Kryptoroxx]

I have the box located near the center console so I will be using something in that vicinity and this time I will make it shiny. Again tomorrow I will hopefully not feel like a road paver ran over me and get this done. Once I have a positive rest I will run the wire and be done with wiring for a little while.

[Seanz0rz]

Lol, tell me about it. Ran a ton of wire in the garage today for the freezer and future garage door opener, washer/dryer, lights, and 2 20 amp circuits for tools and stuff. Spent all day on it. Dad did most of the work since I hurt my back moving a safe yesterday.

[Kryptoroxx]

Lol, tell me about it. Ran a ton of wire in the garage today for the freezer and future garage door opener, washer/dryer, lights, and 2 20 amp circuits for tools and stuff. Spent all day on it. Dad did most of the work since I hurt my back moving a safe yesterday.
Wow.....that just makes me feel more tired! However I'm glad you got that done. Should be pretty nice in your garage soon.

[Seanz0rz]

It'll be another 6 months until anyone calls it "nice". But, it is getting there.

[Kryptoroxx]

Finite! Well at least the wires are. It was a ground issue and it cleared right up when I used a different ground.

Sean you provided an almost perfect length in the harness I provided a pic below but I would guess about 3-4ft extra. I prefer shrinking a harness over having to lengthen it. Now this weekend or maybe next weekend I will be heading to the hobby shop to do the elocker retrofit.

http://imagizer.imageshack.us/v2/800x600q90/674/nfXXv2.jpg (https://imageshack.com/i/iqnfXXv2j)

http://imagizer.imageshack.us/v2/800x600q90/661/9tgE2g.jpg (https://imageshack.com/i/id9tgE2gj)


So while I was under my truck I noticed the passenger side lbj and saw some grease. Seems that there was a hole poked in the boot....but the joint itself is tight as a drum. Just curious if that is a sign of replacement or whether I should stuff some more grease in and call it a day.
http://imagizer.imageshack.us/v2/800x600q90/909/ELH4VQ.jpg (https://imageshack.com/i/p9ELH4VQj)

http://imagizer.imageshack.us/v2/800x600q90/537/efFkPc.jpg (https://imageshack.com/i/exefFkPcj)

http://imagizer.imageshack.us/v2/800x600q90/538/6aFcVB.jpg (https://imageshack.com/i/ey6aFcVBj)

http://imagizer.imageshack.us/v2/800x600q90/661/WRhF5A.jpg (https://imageshack.com/i/idWRhF5Aj)

[Seanz0rz]

So glad it works for you!

I figure it's always easier to make the harness a few feet shorter than it is 1/2" longer!

Mine leak too. They aren't too bad so I wouldn't worry. I will probably replace the boot at some point, but the joint feels great.

[Kryptoroxx]

Well everything is back up under the truck today. I filled the diff with lucas 80/145 as I have no idea how many miles are on the diff. I will update with a few custom things I did to make the installation better.
I am waiting on the front diff till either this Friday or next. My fingers hurt, the family is sick, and I can't stay in the hobby shop tomorrow night. Lauren is still my dd.

[Kryptoroxx]

Finally got around to replacing the front diff. Everything went well but if anyone else tells me the front diff practically falls right out.....they're lying. It did go back in a lot easier than it came out though.

[Seanz0rz]

Glad you had a better time with it than I did. I fought it forever to get it in.

[Kryptoroxx]

Glad you had a better time with it than I did. I fought it forever to get it in.

It took a good 5 minutes to wiggle it back in to be sure but I used a jack to lift it into a spot and then wiggle it past an obstacle...and then lift a little more. I also had a buddy helping me. He wheels a jeep and for most of the time I kept hearing "...man I'm jealous, you know how long this would take on my jeep?" lol. A helping hand is what really made it go quick.

[Seanz0rz]

Help would have been wonderful. I suspect your 4 cylinder oil pan is probably a little more forgiving in the space dept.

[Kryptoroxx]

I would be willing to bet you're right. BattleWagon always comments on how much space I have in the hood so I imagine the same is true under as well. The one snafu that I had was I forgot my diff fluid when I went to the hobby shop so I had to fill the diff when I got home lol.