Removal of transfer case

[bulldog]

Here are the instructions for removing the transfer case. Teh manual calls for taking out the whole transmission. I think if you can get access to the bolts you will be able to just drop the transfer case and save a lot fo effort and time.

They call for 8 bolts that connect the transfer case to the transmission, 5 bolts from the transfer case side and 3 from the transmission side by the looks of things. They also mention 2 clamps, 1 will be the bretaher, not sure abou the the second. And obviously the electrical connections.

[Joel]

Thanks Andries!

[AlexJet]

Sorry, a lttle off-topic, but interesting info.
Look carefully at 1st page of the pdf file. There is a skid plate there.
1. The middle portion has plastic plug for oval hole.
2. The rear part is huge and looks like was designed to have full cover of the transmission.
I don't have #1 and I have small plastic piece instead of the full #2.
Where this pdf file coming from, 4Runner? Hmmm????

[Joel]

My new (to me) tc should be here tomorrow. Kurt and I are thinking about creating the most unused write up ever - tc swap in a 4th gen. :flipoff:

[Cruiserhead]

LOL
I think it will be a good resource to have even if it is NEVER used again! LOL

Maybe it will be helpful w/ you guys slap crawler boxes in there ;)

[bulldog]

I think you guys should do a nic write up as it always comes in handy in the future. I found I have used my own write ups more often than not :D

[Joel]

http://joelrasmus.com/temp/newtc.jpg

:guitar:

[bulldog]

Looks brand new!!!

Enjoy the install :D

[Mikestang]

Yea, now show us a pict of your xfer case!

[my034runner]

Is that a new T-case, or were you lucky enough to find one at a junkyard? :D

[Joel]

Lucky enough?

http://www.car-part.com/cgi-bin/search.cgi?userSearch=int&userPID=1000&userLocation=All+States&userIMS=&userInterchange=BBCBD&userSide=&userDate=2004&userDate2=2004&dbModel=73.2.1.1&userModel=Toyota%204Runner&dbPart=412.1&userPart=Transfer%20Case&sessionID=915&userPreference=zip&userZip=89123&userLat=36.0179&userLong=-115.1517&userUID=0&userBroker=&userPage=1&iKey=

[my034runner]

Lucky enough?

http://www.car-part.com/cgi-bin/search.cgi?userSearch=int&userPID=1000&userLocation=All+States&userIMS=&userInterchange=BBCBD&userSide=&userDate=2004&userDate2=2004&dbModel=73.2.1.1&userModel=Toyota%204Runner&dbPart=412.1&userPart=Transfer%20Case&sessionID=915&userPreference=zip&userZip=89123&userLat=36.0179&userLong=-115.1517&userUID=0&userBroker=&userPage=1&iKey=



Nice! That's a nice resource for used parts. :moon:

[Joel]

All done! Wasn't hard at all. 8 nuts, 8 bolts. I'll post some kind of write up soon.

[bulldog]

All done! Wasn't hard at all. 8 nuts, 8 bolts. I'll post some kind of write up soon.
:bigok: Kewl, so now you are back in business again.

Good to know it's not that hard. I thought the top bolts might be a pain. opw you guys too some good pics :guitar:

[Vegas Runner]

All done! Wasn't hard at all. 8 nuts, 8 bolts. I'll post some kind of write up soon.

Not hard maybe but painful. It looked like that was about a $850.00 setback, based on that link you gave! That makes the trip one expensive weekend. Did the part you purchased have a core return requirement or do you now have a spare transfer case?

BTW - I was very impressed with the way you dealt with the situation in the field. It would have been easy to not have handled it as well.

[Joel]

Stubbs (stubbs welding) is such a stand-up guy that he has offered to pay the cost of the used tc. The way he is standing by his name is very impressive.

Cost of the tc was $650 +$100 shipping/handling. No core. My cracked one is going to stubbs.

And thank you!

[expat]

Props to Stubbs. Big Time!

[Mikestang]

Wow, now that's a stand-up company. I like dealing with people like that.

[Joel]

Here is a picture of the repaired crack on the old case.

http://joelrasmus.com/temp/tc-patch.jpg

[Cruiserhead]

look at that beautiful repair job :D

Glad it worked out w/ Stubbs and you are not out of pocket :beer:

[expat]

So was there a write up? I've searched and not having any luck but I thought I saw a write up a few years back?

[Joel]

I never got around to a write-up. It was a pretty simple procedure.. only pain is dealing with positioning the heavy tcase, everything else was very straight forward.

[prjeff46]

I guess I missed this whole story but what exactly did Stubbs have to do with the cracked transfer case? Sorry I am a little late on this. Could you post a link to the story? Thanks.

[Photog]

Joel,
The instructions at the beginning suggested removing the tranny & t-case together, then separating them.

It sounds like you just left the tranny in place, and swapped out the t-case.

Were the upper bolts difficult to get to? Plugs, wires, sensors, etc?

[Joel]

I guess I missed this whole story but what exactly did Stubbs have to do with the cracked transfer case? Sorry I am a little late on this. Could you post a link to the story? Thanks.

He designed a tcase skidplate that with little pressure bent the mount till it cracked. (There was space between the skid on the tcase) Was fixed on the trail with some loc-tite version of pb-weld.

Joel,
The instructions at the beginning suggested removing the tranny & t-case together, then separating them.

It sounds like you just left the tranny in place, and swapped out the t-case.

Were the upper bolts difficult to get to? Plugs, wires, sensors, etc?

Wasn't too bad, the upper bolts req'd a few extensions to get to. I think one of the sensor plugs was a but of a pain but overall it was a pretty straight forward (pretty easy) swap.

[97kurt]

Having two people to get it back in place is highly recommended. One person to lift (aka bench press), the other to guide it into place and jiggle the output flange so that the splines line up. Once it slides into place you are good.

There are no seals to deal with and there are no linkages on the AWD/Full time case that Joel had. Removing the one in my truck would be a lot more work.

[prjeff46]

gotcha thanks...it was cool of him though to back you up

[expat]

Yeah, the only thing I was wondering (actually two things) were, did you replace any seals, and did you drain the transmission.

Actually the only part that looks tricky on the instal is getting the breather tube on top plugged back in to the t-piece. Its on top opf the case and looks difficult to reach up to. I was thinking of just making the tube longer and connecting it before lifting it up.

[Ludedude]

Having two people to get it back in place is highly recommended. One person to lift (aka bench press), the other to guide it into place and jiggle the output flange so that the splines line up. Once it slides into place you are good.

There are no seals to deal with and there are no linkages on the AWD/Full time case that Joel had. Removing the one in my truck would be a lot more work.

They have these awesome things called jacks now, maybe the news hasn't traveled that far North yet? :rotflmao:

[expat]

They have these awesome things called jacks now, maybe the news hasn't traveled that far North yet? :rotflmao:

I think its easier to just do it with two people.

[97kurt]

They have these awesome things called jacks now, maybe the news hasn't traveled that far North yet? :rotflmao:

The jack just got in the way.


As for the breather, I'm pretty sure it was within reach. But two extra barbs and 12" of tube to make a little extension might save you some headache.

Side note, chalk the wheels and set the e-brake. Cause "park" no longer exists once both drive shafts are disconnected.

[bulldog]

x2 on the jack just being in the way. It actually hindered us in getting the thing out. Almost caused the transfer case to pinch Mark's arm badly.

[Ludedude]

Interesting. I was being more facetious than anything but good to know for those who need to deal with the transfer case. :)

[Photog]

From the description (no seals) it sounds like the tranny and T-case do not share fluid. Is that true, or are they connected with a tube & O-Ring?

[Mikestang]

They do not share fluids.