Swapping Input Shafts for FJ Case for Manual Transmission

You know, it's likely easiest to just grab a manual transmission transfer case and swap the parts. There's a cheapy close by I'm going to try and grab.

Wondering, though, if you'd add a consumables or parts list to this thread.

Likely need a new input shaft oil seal and some FIPG but is there anything else? Can all the snap rings be re-used if you're careful?

 

You might post up a WTB thread here on TW. I have sold two of these to other members in the past. I started out buying a spare 6spd taco transfer case for my swap, cost me about $250-300 iirc.

It will likely be cheaper to buy a used case and gut it vs buying new parts

 

When I swapped input shafts around I believe I was able to reuse everything except for FIPG obviously.

 

I'm picking up my 2020 4Runner stick t-case from Gundies (wrecking yard network in the PNW) on Monday. Turns out they have a 2014 manual Tacoma transfer case for $123. That was easy! Thanks for posting

 

Can anyone confirm the part number for the manual trans/transfer case input shaft seal?

It's not clear to me from the diagrams whether it's 90311-43007, 90311-43008 or 90311-43021. Or is it both 007 and 008 that I need to order?

This diagram includes the o-ring (96721-35063) so assuming it's the correct diagram for the manual trans t-case input shaft assembly.



But then goes on to list two part numbers for the seal


Am I right in assuming there are 2 seals here?

 

I finally got the seals from Toyota Overstock (20 days from order to delivery! Not stoked)

Anyway, just to clarify, the original post (@EatSleepTacos ), am I swapping the big automatic planetary ring gear into the 6spd planetary/input shaft assembly? I want the FJ t-case to mate up and shift right with my 6spd RC62 manual tranny.

 

the fj case to mate to the 6 speed will need the larger 22 spline input shaft.

 

Yeah, gotcha. I was swapping input splines for the 6spd manual (RA and RC) following this thread. I had a moment of confusion with the need to swap the big planetary gear but it all clicked and my new FJ Case is back together and ready to mate to my RC trans once I clearance it for the shift rails. Maybe I was huffing too much brake parts cleaner or confused as there were no less than 3 transfer cases within arms reach of me at the time but got it figured out. Thanks for responding again @6 gearT444E

 

How long does the conversion typically take people? Sub 8hr/one day?

Has anyone bought a cheap used Taco tcase, to make swapping parts between the two (FJ case) easier?
That way, all the parts can be prepared on the bench in spare time
while the truck still drives and doesn't go down for surgery

given the work of swapping components over seems to require a shop press as well
not to mention preferred exterior cleaning, letting sealant cure upon re-assembly, etc.

seeing taco tcases online from junkyards ~$150

I believe I have gathered so far:
-auto FJ tcase, has stick but no knob
-Taco front diff, as a spare to regear as well

hoping to do twin stick, if I can figure out how to. Both a nice-looking location to put it (6MT), and how exactly that's done given I don't have a welder.
2LO sounds like a nice feature to have

I'll take a look to see if my spare front diff has had anything done to it, or still needs stuff like OEM ADD-less/delete tube and whatever else that requires

best looking install I've seen so far is this one on an FJ using front range twin stick kit, bent in a vice with cheater pipe

 

I would say you can do it in a day to get it back up and running, but getting the floor sealed up and shifter where you want it takes longer. There is also no need for a shop press, I did this in my garage with basic hand tools.

edit: at least my method could be done in a day. I turned the truck to 4HI and then unplugged the 4wd ecu, essentially locking the add into being engaged full time.

 

swapping the input shafts should take no more than half a day, no press work or welding required.

 

just something you might want to check also.
the transfer case chain make sure its got no slop or like me you'll be taking it apart again.

 

Do you have info on what to do for the blinking lights on the dash.

 

sorry I don't. I was ultra lucky that the tech at my (dealership) made it work somehow. maybe @6 gearT444E could assist?