UPDATED - Now with Twin cases and triple sticks "El Taco Diablo" 4x4 swap and B.S.

Crossmember mount is done

 

Waiting for word back from Trail Gear on how I'm going to fix this coupler issue.

 

Those (4) bolts need to come out and (4) off of the trans mount. Bearing needs to come out on autos.
https://www.tacomaworld.com/threads/official-crawlbox-bs-thread.422186/page-51#post-21143177

 

Not totally following you here, and the link to the Trail Gear PDF in that thread is broken.

The bearing comes out and stays out... I.E. no longer a bearing in that location?
Also, what about their seal? The provided coupler doesn't pass through the seal. Is the spline from the front case what makes the surface for the seal to ride on?



Kinda irks me on Trail Gear. The kit says it will work on manual and auto, but their steps only show manual now.

 

TG Links are dead, but I have uploaded in that thread Inchworm/LowRange pdfs before they were removed.
Bearing comes out and stays out.

1. Remove Trans to Tcase adapter housing via 4bolts surrounding output shaft, and remove 4 bolts on the same housing from the transmission mount.
2. Remove C clip, seal, and bearing from housing, reassemble.
3. Mount splined coupler onto output shaft of transmission
4. Install aluminum housing into new larger housing hole around spline and output shaft splined coupler (with red Loctite)
5. Install seal at end of aluminum housing.

 

Right on man... Thank you.

Ya, I guess that bearing is kind of redundant anyway. There is an output bearing at the end of the (actual) transmission, before the T-case adapter.


The T-case mount bolts have already been removed, due to the fact I removed the crossmember to fully weld the T-case mount "pad", "ledge" thing that the tcase mount will now bolt to.

 

This should help, better visual. These crawlboxes have a few nuisances that if not done right will cause issues (fretting, leaking, chatter, shifter pop out, etc.)
https://www.tacomaworld.com/threads/official-crawlbox-bs-thread.422186/page-27#post-18255484

 

Anyone happen to remember the torque spec for the tcase adapter to trans bolts?


Edit... got it... 27 ft lbs

 

I was looking at the AT specs

 

Mated the cases to check the shifting etc.



Glad I did, cause there was a problem getting it to go in Low on the Jshift case.

I believe I got it all worked out. The jshift is shifting properly now. I'll mate them back up tonight to double check.

I got the tcase adapter off and the bearing out. Tcase adapter went back on, all sealed up.

Hopefully I can get the crossmember back on tonight and start getting some forward progress on this project tonight.

 

Forgot to follow up on this.

The Trail Creeper transfer case comes with Trail Gear's shifter. Complete with new heavy duty spring.

 

What is everyone using to seal that aluminum seal where that output bearing was in the tcase adapter?

 

I used gray Permatex. I also put is shit ton of it in the coupler when I mated the crawlbox to the trans.

 

I like the gray permatex idea, because that's what I have lol

So you put it inside the splines coupler (to keep it from pulling off the spline if//when you have to pull the front case off the trans?

 

I put it in the coupler to prevent 2 things. First is the mixing of trans fluid into the crawlbox. Second it to prevent fretting. Most guys use anti-seize in the coupler to prevent fretting. Anti-seize can wash out so I just sent the fucker with gray. lol

 

But, I'm assuming you didn't permatex both ends of that coupler, correct? That way, if you need to split the case from the trans they don't stick together, correct?

Or did you fill that fucker with permatex?

 

Just on the trans side but I used a shit ton of it.

 

Right on... I will do the same.

 

Ok... I hate asking so many dumb questions, but write ups are hard to come by and the instructions from Trail Gear are for shit.

I noticed 2 "extra" bolts in the hardware pack.

They happen to thread in to two of the holes in the adapter plate, but they are WAY too long to actually belong there. And they aren't mentioned in the instructions. Red circles.




So I'm thinking they are "extra."

But it begs the question... the areas circled in orange will allow gear oil out of the front of the case. The Jshift doesn't get sealed with Permatex to the Tcase adapter... but I guess the front case will now need to be sealed to the Tcase adapter? Correct?

The blue arrow will be sealed with the seal I just installed in the Tcase adapter. I'm assuming that keeps the Trans fluid out of this area, and gear oil will need to be sealed IN to this area now.

 

https://trail-gear.com/media/downloads/pdf/instructions/107517-1-INS.pdf

Here is a new link Trail Gear sent. Answers the questions on the coupler that @theesotericone and @ToyRyd04 already answered. lol

Still doesn't really answer the questions about sealing adapter to tcase adapter... it mentions "provided bolts and washers" for those holes, but the bolts "provided" appear to long, there were no wshers provided.