Transfer case reseal

02 dc auto 3.4
Heres a question I cant find any info on, the rear half of the transfer case houseing can it be removed while still on the transmission in the truck im asking this because my hole for the fill plug is stripped clean and the plug can no longer grip and id rather just replace that part of the case then use a heli coil or some form of thread repair.

 

Before getting too crazy I'd suggest trying to see if you can take a Dremel and turn that thing into a big flat head and see if it will come off(probably use a chisel at that point to turn). That or one of the reverse drill bit extractors. And last but not least you got this option too (pricey), irwin industrial tools 54125.

I have the exact same issue funny enough so I'll be working on it this weekend too. I'll let you know how it goes. Have you been able to locate a replacement bolt? I haven't had a chance to look, if you have a part number that would help me out greatly.

 

The plug is fine its the case the threads on the case are gone. And I want to know if that half of the case can be removed with removing the transfer case.

 

Interesting problem. I couldn't find any answers either. I have the FSM, and it assumes that the TC has been removed, for dismantling. It would be cool if it were doable.

You might get an answer from MarlinCrawler. They have a forum that you could join and post the question.
http://board.marlincrawler.com/

If it were possible, it looks like you'd have to first remove the rear flange (staked nut, need a puller), then the speed sensor, then the rear extension housing (5 bolts), then the little skid plate, then the rear case itself (12 bolts). Who knows what little parts may, or may not, fall out during the last step.

 

My apologies. I was reading that and totally misunderstanding it this morning before work. Good luck!

 

Can someone send me a link or something to the fsm for these transfer cased. If it was a manual transfer case i would have already torn it down but these are different and id rather not open it up and have it fall to pieces and end having to pull the whole thing out anyway, which do you have to pull the trans in order to pull the transfer case?

 

After giving you a shitty answer you peaked my interest, hope this helps if not I promise I won't open this thread again lol.

Go to this thread and the last comment has a PDF of the FSM.

http://www.yotatech.com/f2/tacoma-transfer-case-options-107957/

 

I dont see why not, but i'd like some one to chime in who has had there transfer case apart.

 

If you are planning to replace the transfer case rear half , you have " NO " choice but to remove the transfer case .
As mentioned above , why not just use a heli-coil and be done with it rather than a complete rear half ?
I have rebuilt thousands of transfer cases and have never tried to replace the rear half when its still bolted up .
Is it do-able ? Probably but why not just remove the complete unit and wash everything down properly if you plan to go with a rear half repair

 

No need to pull the tranny, the TC unbolts from the tranny. Tranny jack helps, its pretty heavy.
You'll need to support the tranny with a floor jack since the rear 'motor' mount is attached to the TC. You will likely need to remove the cross-member. I've done this on a hilux gear-driven case a couple of times, but not a Tacoma. Not fun without a hoist.

 

If it was my problem I would be considering in place fixes
something like :
<iframe width="560" height="315" src="https://www.youtube.com/embed/AnP1HQkq70s" frameborder="0" allowfullscreen></iframe>

 

Well shit

 

I did it with no jacks or anything. It was pretty easy.