Transfer case problem. Replace or rebuild? Any T case sellers?

Hello

I have had a shop diagnose my truck with a bad Transfer case. No other information from them.

When I place the truck in 4wd (4hi,4lo), the Transfer Case makes a clanking/popping noise when the front wheels lose traction, such as in gravel or sand or snow etc.

I have no idea what is wrong with my current T case.

I have to do this without breaking the bank, as I just spent about 3k on the truck already.

Anyone else have this issue? Anyone have any advice? Anyone have any Transfer Cases I could buy?

1997 SR5 extended cab, 5spd MT, Without diff lock, with Automatic Dif Disconnect

 

Just got news that the chain was really lose and the oil was blacker than black, and we just had the fluids changed.

 

That is odd news but good news, hopefully. Do you use the 4wd frequently or work it hard? Maybe a gear lost a tooth to allow excessive play in the chain? When they drained the old fluid were there any chunks on the drain plug or in the gear oil?

 

We would love to be able to use our 4wd drive again, we do use it pretty often when we can. As a daily driver it is fine though.

They did not note any parts or teeth fall out of the case.

I have tracked down a few replacement T cases just in case it's fragged.

That being said, how difficult of a replacement is it? I've done the clutch before, that was a pain but easy. The guy at the shop said that they might have to pull the Transimission out to get to it though.

If I can just pull the Tcase and slide a new one in that would be great.

 

i bought a new t case for 100 bucks and it works great! super easy to replace. drop the tranny mount, remove all bolts and it slides off!

 

no way do you have to pull the tranny!!! that insane. the t case slides straight off the back. do it yourself!

 

Oh that is good news! Now that I know it comes off by itself I feel pretty confident that I can do it myself.

Thanks!

 

I've done my clutch and this is WAY easier! Make sure you put the tcase in 4hi when you remove the lever though.

 

Gotcha, to make sure I know where the level is positioned.

I was just under the truck planning it all out, should take maybe an hour to clean it up and pull it out.

I can't tell you how much I appreciate the advice. I'll update once I get it done. Should be maybe w week before I get to it.

 

No problem! If you run into any problems shoot me a message. Also my truck is a 5speed and I used a tcase from a auto.

 

And it fit okay? Was there an issue with drive shaft length?

 

TThe only difference was the input shaft. The manual one was longer but the auto worked just fine even though it was shorter! Driveshafts are the same

Manual is one closest to camera

 

Update:

I replaced the Transfer Case myself after finding lots of play in the output flanges. I got a used unit from a yard, out of a 1997 4Runner. The only difference was the slight length of the shaft and the worm gear for the speedometer. I pulled the 2 point sensor from the new one and used the old worm gear from my old one.

Note:

When ordering the output seal for the transmission, they had 2 different types in the system at the store. I ordered the wrong one the first time, the proper one is all rubber versus a metal cased seal with rubber backing.

I was teaching my fiancé some of the finer points of wrench turning so we kinda milked the job over a 3 hour span, but it could be done in 1.5-2ish.

 

Did you use one from auto or manual?

 

It was from an automatic. The only difference was a slight difference in length of the input shaft. It mated flush and works properly so I am going to call it a win.

 

Worked for me too

 

Appreciate your help buddy.

I just love this forum. I used to have another account but it's been so long I forgot my login info. Glad I'm back!

 

Resurrecting this thread. I've crossposted here.

So according to the above, I should be able to put a transfer case from an automatic 5ZE-FE into my manual 5ZE-FE. Before I pull the trigger on this, I just want to confirm that this is correct. The "new" TC is from an automatic 4Runner Limited.

Thoughts? Anything else should know or consider? Thanks in advance!