Hilux MK5 2.5 2003 - New E Locker fitted, but not engaging

[TobyH]

When I bought the vehicle I noticed the Locker sign on the dash just flashed when in Low and with Locker button pressed. I thought fine, I'll deal with it after purchase.

I then got it home and had a look. Fuses all ok, I can hear a relay but no movement. I took the locker unit off and opened it up. Not good, so decided to splash the cash and get a new one.

I have now fitted the new one. When in Low (4wd light on) with engine running I press Locker button and hear the motor engaging, but Locker light still flashes. Car is on stands so I turn one wheel, other wheel goes opposite direction (i.e. locker not engaged). I get car off stands and drive it forwards and backwards a couple of times, still light flashes. I now have it back on stands but cannot see why it isn't engaging the locker. I can only think that the gear isn't engaging properly or the slider in the diff is broken/missing.

Any ideas?

 

p.s. I did check that it locked before I got the new elocker by hand with a screwdriver sliding the locking mech over. So that rules out the lack of issues with the mechanism in the diff.

Edited May 26, 2023 by TobyH
more info added

[TobyH]

Sorted. Removed the unit. Double checked the slider was in the off position. Put all back together. Ian on, 4wd, pressed locker button - initially flashing but turned a wheel and bang, in she went.

[flash22]

Did you align the marks before installing the actuator ? OK never mind

[TobyH]

Which marks? On the housing or with the gear/slider?

Seems to be ok now, but would be handy knowing how to do it properly🤦‍♂️😆

[flash22]

The marks on the housing and shaft/gear, but plugging it into the car and cycling it a few times does the trick (make sure you leave it in the off position) before stuffing it in the axle

most of the 4wd trucks use the same design, water ingress and rust due to failed seals are common iirc you can get all the rebuild parts

random vid off youtube

https://www.youtube.com/watch?v=aqPmA0J0Zco

 

[TobyH]

17 hours ago, flash22 said:

The marks on the housing and shaft/gear, but plugging it into the car and cycling it a few times does the trick (make sure you leave it in the off position) before stuffing it in the axle

most of the 4wd trucks use the same design, water ingress and rust due to failed seals are common iirc you can get all the rebuild parts

random vid off youtube

https://www.youtube.com/watch?v=aqPmA0J0Zco

 

I saw this vid, it's just the last part where he installs it that I wanted to see the line up, but you can't see it🙄.

Thanks for the pointers. Fingers crossed it will last a little while before I need to change/repair it again...