Let's see your FJ case swap

Thanks for all the info fellas!

As far as write ups the only thing I guess I need to know is about the input shafts. If I remember correctly you only have to open up the FJ case to swap inputs if your adding the FJ case to a 6 speed manual/V6. Is that right? The 5 speed manual/4 cylinder is a direct bolt on from the automatic FJ, I think.

If you do ADD delete then you don't really have any wiring to do. All the sensors on the T-case are direct plug ins aren't they?

For you guys running ADD delete, are there any downsides for street driving, like bucking when turning with the steering at full lock?

 

If you do the ADD delete, the differential still functions normally. You shouldn't have any "bucking" unless you are in 4wd.

 

The 6 speed transfer case uses a larger 21 spline input shaft whereas the automatic is 23 spline. The 23 spline came in the automatic FJ case and will match up to your automatic tacoma or 5 speed manual tacoma. Take the sensor plugs off the tacoma case and swap them to the FJ case.

There is still wiring to do if you want the dash lights to function correctly, you have to take the sensor wiring under the dash and bypass the 4wd ECU and wire them directly to the dash panel. Of course this isn't necessary for it to function but is a good feature to have. The wiring is necessary for those of you with VSC/TRAC/ATRAC to work if you have them, since the traction control ECU gets the 4lo transfer case signals. If you have a TRD e-locker you will also have to do the "locker anytime mod" to divorce control of the locker from the 4wd ECU since it will no longer be performing any function.

Yesterday we took action to get another member electronic free, and pulled @MY50cal 's drivetrain to do the swap


No downside to the ADD delete other than the front driveshaft and ring gear spinning all the time which results in a small parasitic loss and possibly increased wear on the front diff. But if you look at the 6 speed FJ cruisers, they were obviously designed this way from the factory so it has already been evaluated by toyota engineers to be acceptable.

 

Hmmm, any takers on a swap party in CT? Id like to do mine. For the front end, I thought about either the manual hubs, FJ tube, or most likely just engage the fork with the add and leave it.

 

I’d be happy to lend a hand but Ct is a bit far for a mod meet for me.

 

Thanks again guys!

I'm gonna read through the whole thread then come back with some more questions if I have em.

 

Whew! Just read through the whole thread and I have some more questions.

Why exactly is the ECGS bushing necessary? IIRC it's purpose is only to solve a vibration problem in trucks with higher lifts and higher CV axle angles. Is the bushing swap required for optimal performance of the FJ case? Will it make shifting smoother or something?

Also I'd like to thank @6 gearT444E for post #176! The RST thread is inaccessible right now so that's the best explanation of the required wiring I've seen so far.

As far as 4Runner T-cases vs FJ T-cases, it seems that manual trans Tacomas newer than 2010 wanting to do the swap can use either an FJ case or a 4Runner case because from 2011 and on, the Tacoma used the ABS sensor for vehicle speed information rather than a worm gear in the tail shaft. The FJ case has provisions for the speed sensor even though it was not used on automatic FJs, so manual trans Tacomas from 2005-2010 need only to remove the block off plate from the FJ case and bolt in the speed sensor from their Tacoma T-case. The 4Runner T-case (5th gen?) does not have this worm gear for the speed sensor.

For manual trans Tacomas 2005-2010 wanting to do the swap, they could use a 4Runner case but would have to somehow swap in the worm gear that interfaces with the small white plastic gear on the speed sensor. That likely requires separating the T-case and getting into the internals. However this step could be avoided by simply selecting an FJ T-case for the swap because the FJ case already has the worm gear for the speed sensor.

Does all that sound right? It's a bit confusing to me so I tried to lay it out clearly. The main benefit of the (5th gen?) 4Runner case is that it can be found with lower mileage, right?

That leads to my final question right now, is there a mileage threshold that should be avoided? My truck has about 46,000 miles so anything around there would be fine I think. Obviously less is better but what do you think is the cut off for consideration?

 

I just checked my truck, 2014 5 speed manual. It has a block off plate. No gear driven speed sensor. That means I could source a 4Runner case.

 

To remove the needle bearings from the equation. They go bad even when the axle isn’t constantly spinning.

 

So I just spent a few hours cruising ebay looking for T-cases and I have made a few observations...

Finding an FJ case for under $400 is no problem, even with free shipping. But mileage will be high.

Finding a low mileage FJ case is not easy. Most have over 80k miles and many have over 100k.

There seems to be a lack of consistency with the lever shifted 4Runners. Some listings say that a 4Runner case is compatible with the FJ vehicle but when photos of the interior of the donor vehicle are displayed you can clearly see the presence of an electronic 4wd dial and no shift lever.

It's easier to find a lower mileage 4Runner case because they are more recent but it's not always clear if the case will have a lever or electronic actuator.

 

I see. So it's just kind of a preventative thing. I'm guessing if the needle bearing comes apart it could do some damage to your diff.

Also @HolyHandGrenade if you don't mind me asking, what did RST want for a ready to go FJ case? They have no prices on their site.

 

He used to charge like $1100 I believe

 

It’s been a couple of years, but i believe it was 12-13 hundred with the twin sticks and RST shift knobs. I gave the shift knobs to @stairgod thiigh. I prefer the stealth look.

 

Most of those miles tho arnt in 4wd soo the load on the t case really isn't much...I'm sure you could source any of the bearings if they were bad when u pull it apart.

 

I just want to know where u can get a twin stick base

 

Make one.

 

I did mine at +100K in the clock.

They are slow as a turtle walking uphill on glass but look at Davez off-road for the twin stick assembly as an alternative source.

 

My thigh thanks you

 

That's not too bad really, some of the used FJ cases with low miles were going for $700-$900.

That's a good point. If most of the miles aren't 4wd then there'd be not much worry about bearing wear, at least on the front drive output. Is chain stretch a thing?

 

Only the 4Runner trail/TRD off road has the manual T case.