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Transfer Case Disassembly

Discussion in '1st Gen. Tacomas (1995-2004)' started by Washout, Oct 4, 2017.

  1. Oct 4, 2017 at 5:37 PM
    #1
    Washout

    Washout [OP] Active Member

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    TRD supercharger, 3" lift, 33" tires, front air locking diff, onboard air compressor, front steel bumper
    Hey guys, I need to take apart my transfer case to fix a broken off drain plug. I am looking for anyone who has taken apart a transfer case for a vehicle similar to my 2002 Manual Tacoma. If you have or know of any videos or forums that have covered this please let me know!
    Thanks!
     
  2. Oct 5, 2017 at 8:22 AM
    #2
    Glamisman

    Glamisman Well-Known Member

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    do you have a picture... this might be "fixable" w/o a R & R being involved.
     
  3. Oct 5, 2017 at 8:40 AM
    #3
    Washout

    Washout [OP] Active Member

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    TRD supercharger, 3" lift, 33" tires, front air locking diff, onboard air compressor, front steel bumper
    [​IMG] This is where the plug broke off, the only access to a welder I have is in a metals lab, and I don't think my truck will fit through the door
     
  4. Oct 5, 2017 at 9:18 AM
    #4
    Glamisman

    Glamisman Well-Known Member

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    it looks to me like you can thread the old drain plug back in and not hit anything correct? if so, there is no reason that I can see where you cant get a new drain plug, drill and tap the center of that and put say a 1/4 pipe plug in it. If you clean the the threads and apply a "permanant" type of adheasive/sealant and screw the new plug in it should work. If/when you want to drain the oil counterhold the original plug when you take the pipe plug out... just dont over torque the pipe plug and split the drain plug... pipe plugs are tapered. You might be into this repair an hour or 2 and under $20. Drive her around for a bit and look for drips. If it doesnt work as expected you have lost nothing but a little time and a few $ as opposed to lots of work.
     
  5. Oct 5, 2017 at 9:29 AM
    #5
    Wulf

    Wulf auto dismantling & hoarding disorder

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    this seems like a good idea. You can also try a bunch of RTV
     
  6. Oct 5, 2017 at 10:26 AM
    #6
    mechanicjon

    mechanicjon They call me "Jonny Stubs"

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