Drive train rebuild questions

Hello everybody!

This is my first post but I've been a creepier and have read this forum and used it as a search tool for ages. This'll be a long post cause I'm a notorious data dumper/talking rambler so bare with me..

Back story: I bought a 98 2.7l 4x4 manual 4runner with 219k for 200 bucks (cause it wouldn't start) and figured out the previous owner screwed up doing a head gasket job when it was really a cracked head. Pulled the motor and over the course of a year did a full fresh rebuild on the motor (I can get into those details later if you guys really want to know) but in the time it took me to do that the motor work , tweakers smashed the back window and stole a bunch of engine attachments from the back of the runner to scrap for drug money probably... intake manifold, wiring harness, alternator you know crap like that. So instead of paying all that money just to get the runner back to stock I decided to buy a similar tacoma to drop the freshened motor into. Much searching and gnashing of teeth I've finally procured a 98 2.7l 4x4 manual ext cab tacoma with 229k on it, got a great deal cause the truck needs a clutch and cyl 1 has horrible compression.

The truck owner told me that the guy he bought it from but in a used tranny a couple years ago and when I inspected everything in the sun the next day this other transmission is wet, like SUPER wet at every seem, same with the transfer case. Meanwhile the 4runner transmission is dry and worked okay for the 2 months I got to drive it before pulling the motor. Both vehicles have the W59/VF2AM combo

So my question; would it be better for me to take the tranny and transfer case from the runner and mate it back up to the new engine then drop the whole shebang into the tacoma? Or rebuild the tranny in the truck so it's new as well? I want to freshen up the transfer case but I can't find a good resource for a rebuild kit for that VF2AM case.

Or since it's not leaking should I just change the input/output seals and call it good? I don't know what kind of life the gears, bearings and syncros have nor the chain in the transfer case.


Side question; during my inspection on the truck the center (carrier?) Bearing for the driveline has zero rubber left in the insulator, should I change all three ujoints st the same time I swap the bearing?

 

Welcome!

That's an interesting story lol.

I would say go ahead and rebuild the tranny/case if you have the tools/experience so you don't have any problems. This will give you peace of mind since you have a rebuilt engine going in and you will have a rebuilt trans/xfer case too.

Change all 3 joints as well for the driveshaft. Unless it's a double cardan then there is a write up for it but you would be better off getting it rebuilt.

My way of doing things: While you're in there, might as well replace with new so you don't have problems.

 

I'm a small engine mechanic so I'd like to pretend that I have the experience/knowledge but tearing into the engine taught me ALOT I knew nothing about lol

I agree with you on doing the work while it's out and while I can but I can't find a good resource on service parts for the xfer case. I can buy the trans rebuild kit from cobra transmission and it comes with everything I'd imagine (bearings, gaskets, seals and syncros) but I'm lost with the xfer case.. if I buy them individually like I'm afraid I'll have to, what would you recommend? Seals, bearings, chain .... and anything else?

 

Transmission kit I used for my rebuild:
TK162CWS is the part number

https://www.ebay.com/itm/Toyota-Lex...-and-Synchro-Rebuild-Kit-1992-05/370559031203

As far as Transfer Case: R100 chain driven

Rebuild Kit:
BK195A is the part number

https://www.ebay.com/itm/Transfer-C...-Tacoma-Tundra-T100-4Runner-R100/282948362509

 

Here is some useful info for you

 

Holy Banana pants you are a Godsend! Thank you so much

Just a side note, where did the R100 designation for the xfer case come from? I get way more google hits searching for that vs the VF2AM which is what I got from this site

 

Glad I can help.

Hmm it was a lot of research and I was able to get it a couple years back. Only mentioned a few times in the forums. It seems after 1995 people stopped updating Toyota transfer case info LOL When I find the source I will let you know.

The VF2AM is pre 1995 Pickup

 

Doh! That would explain why I couldn't find anything but the gear drive xfer case rebuild stuff then, thanks again!

PS did you order and or use any of the Yota SST? Most of that stuff I have the Horrible Fright versions of but I was wondering about the seal pullers and setters... or should I just trust picks/screwdrivers to yank em and sockets to set em?

 

Found the part number for the chain on toyota parts catalog and they want 700 MSRP searching for the part number shows Amazon selling multiple chinese equivalents for around 200 ... would you trust it? Is the chain supposed to be a "lifetime" chain? Even pre stressed chains can stretch so I've never really bought into that lifetime nonsense..

When you rebuilt your trans did you do the xfer case as well? What did you do about your chain?

P/N I got and looked up is 36293-35040

 

I am sure you have a lot of this stuff but this is a few things I used:

1) Harbor Freight 3 Jaw Puller Set 2) Seal removal tool

$13 Lisle 56750 Seal Puller , black

https://www.amazon.com/Lisle-56750-Seal-Puller/dp/B0002SRCKG
3) Seal Driver set \
4) Ball joint service kit - I used the adapters and plates to press bearings on 5) Wheel bearing adaptor set - same as BJ service kit. Used the adapter plates and such for bearings 6) Good Punch Set - This is a random link but something like this

$39 OTC 4600 Punch and Chisel Set - 16 Piece

https://www.amazon.com/OTC-4600-Pun...=punch+set&qid=1555591109&s=automotive&sr=1-6
7) Dead Blow Hammer -

Hardware Machinery 68303 4.0 Lb. Neon Orange Dead Blow Hammer

https://www.amazon.com/Hardware-Mac...ow+hammer&qid=1555591406&s=automotive&sr=1-17
8) Brass Hammer -

TEKTON 16 oz. Jacketed Fiberglass Brass Hammer | 30903

https://www.amazon.com/TEKTON-30903...on&qid=1555591372&s=automotive&sr=1-1-catcorr
9) Snap Ring Pliers - Need regular inside/outside -

$27 Channellock - 6.5 Retaining Ring Plier (926)

https://www.amazon.com/Channellock-...fix=snap+ring+pliers+h,automotive,133&sr=1-24
10) Lock Ring Pliers -

T & E Tools 741 Heavy-Duty Lock Ring Plier

https://www.amazon.com/Tools-741-He...+duty+flat&qid=1555591505&s=automotive&sr=1-4
11) My 20 Ton Press
12) Gasket scraper
13) Scotch Brite
14) Bearing Separator set - 15) Large Bearing Separator - 16) Bench Vise - SUPER IMPORTANT as it will hold the trans for you while you take it apart


The chain I would go OEM TBH. It's not an easy task to replace as you will have to tear everything back apart and the front wheels are directly driven off that chain. Imagine putting a chinese chain in there and going off-roading only to have it snap.

I did not replace my chain as it was in good shape. You gotta figure that if the truck hasn't been off road a lot or at all and in 4x4 the chain isn't put through stress so it should still be to factory specs. I cleaned it with mineral spirits, and inspected it for any cracks or wear. Looked brand new. I lubed it up when re-installed.

Here is the site I use for part numbers:

https://partsouq.com/en/catalog/genuine

Type in your VIN and you can find anything you need with an OEM number. I DO NOT order anything from this site I just use it as parts diagram resource.

Here is an example of my truck parts diagram for trans/transfer:
https://partsouq.com/en/catalog/genuine/vehicle?c=Toyota&ssd=$*KwHB9eT_u8CGvIuoopXd15mNraq0xcrHxtTK-IjQgdbJ0K_Vhobb0cjHiY2EnJPq35qahtfO0aS8uYiImpqB187RxqG2_-qOwrHCp6nCwMeekIHR3teXkNDP1ZyTjMfExdbf0JiUiJ6aoai7xcXDudr-9vW3ubS20d7XkcPAmsnDiAAAAABP17YY$&vid=0&cid=2&q=4TAUN61C7SZ050449

One important note:
There is a seal between the trans and transfer case. They do not share fluid. DO NOT mess it up when you put them together. Or you will lose all your gear oil from your trans and start burning it up. It is REALLY easy to mess it up since you have a heavy trans and heavy X-fer case that have to mate up perfectly and it get's a bit difficult to lower the X-fer case on it with a steady hand due to weight. Just something to look out for.

 

Months later I'm finally tearing into this rebuild of mine and immediately I've got questions!

What is this thing? I was prepping the trans for a deep bath now that it's outta the rig and when I rolled it over this little doohickey fell out .... I don't see a replacement one in the rebuild kit i bought (i got the one from Ebay mentioned previously)

 

Perhaps this may help:
https://partsouq.com/en/catalog/gen...T$&vid=0&cid=2&uid=274667&q=4TAUN61C7SZ050449

 

Looks like part of the shifter bushing assembly or possibly what someone did as an aftermarket fix to take out the play in the shifter bushing

https://www.tacomaworld.com/threads...on-your-5-speed-transmission-write-up.338836/

 

Hopefully you can help me more? Tearing into the kit for the transmission, I noticed the split needle bearing under the counter 5th gear isnt included ... did you reuse yours or is my kit missing parts? I'm only half way through the teardown and I haven't checked everything else but it mostly looks in order

I bought the same kits you posted earlier... if I didn't mention that already


Haven't even looked at the xfer case except to take it off the trans lol

 

You dont have to take the detents and interlocks apart , just separate the case halves and mount the center divider in a vise

 

Sonuva diddly ... that sucks, I just followed the FSM step by step and they told me I had to

 

The split needle bearings were not included but were in great shape still. I reused mine

 

@Russianman92

Did you run into this issue with your syncros?
Finally putting it all back together and I'm scared to continue lol