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FJ Cruiser Transfer Case / Drive Shaft Issue

Discussion in '2nd Gen. Tacomas (2005-2015)' started by Jcarp0331, Jul 30, 2020.

  1. Jul 30, 2020 at 7:46 PM
    #1
    Jcarp0331

    Jcarp0331 [OP] New Member

    Joined:
    Jul 30, 2020
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    First Name:
    Josh
    Vehicle:
    Toyota FJ
    Leveled
    So I’ve been on the fj forums and no luck with my issue so I’m reaching out for help. 2007 FJ 6mt so it’s AWD and 200k miles. Transfer case is Low Lock / Neutral / High Lock / High. About 2 weeks ago I noticed a popping noise when I would start off from a dead stop. It’s gradually gotten worse to where it will sound like a machine gun if I take off hard in first and will pop in almost every gear. It’s dependent upon torque load. If I baby it then it makes no noise. I’ve checked everything. Replaced passenger cv thinking that was it and changed fluid in both front diff and tc. Pulled front ds and greased the yoke and ujoints. Greased rear ujoints as well. Noise is still here. It’s coming from the center of the truck around the tc. So I’m left with bad ujoints or bad tc / tc chain. Pulled the driveshaft and all ujoints move freely with 0 play. I can drive around with the ds out if I have it in high lock or low lock. Just high school will act like neutral. I’m unsure if driving around in high lock is putting the torque factor on the transfer case without the driveshaft installed bc with no front ds it does not pop. The transfer case was low on fluid when I changed it. Driving around with no front ds it’s 0 noise and normal as could be. There is a little metal noise on the front driver over bumps but I’m suspecting the sway bar links bc they are bad just not at the top of the list right now. All skid plates are off. Could it still be slack in the chain and causing it to slip a tooth but only doing it when the ds is installed and sending power to the front wheels? Or could it be a bad drive shaft / ujoints. I’m pulling the back cover off the transfer case Saturday to inspect it. Thinking maybe the chain is stretched or the forks aren’t letting it engage into 4wd... had it on the lift today with it running but with no resistance there it wouldn’t make a noise either... has anyone ran into anything like this?
     
  2. Jul 30, 2020 at 7:58 PM
    #2
    ShimStack

    ShimStack Well-Known Member

    Joined:
    Mar 11, 2012
    Member:
    #74701
    Messages:
    1,651
    Gender:
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    First Name:
    Ben
    NC
    Vehicle:
    '91 Truggy, '98 Project, '16 DC OR M/T Locked F/R
    Chain stretch/wear or front output gear wear causing slip/tooth jump at the front output. Without the front driveshaft there's no torque at the front output gear and thus no load in the chain to cause it to jump. Common issue with AWD chain driven cases with lots of miles.

    Good news is a chain swap is pretty simple and a tcase swap is simple too. Plus you can find these complete on Ebay without much trouble and not very expensive. G'luck!
     
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    #2
    ohcaltexscar likes this.
  3. Jul 31, 2020 at 1:52 AM
    #3
    Jcarp0331

    Jcarp0331 [OP] New Member

    Joined:
    Jul 30, 2020
    Member:
    #336123
    Messages:
    2
    Gender:
    Male
    First Name:
    Josh
    Vehicle:
    Toyota FJ
    Leveled
    Thanks Shimstack! That’s was pretty much my thinking on it I just needed someone to confirm. Looks like I’ll order up a tc today then throw this one up for sale dirt cheap for anyone looking for a swap.
     
    ShimStack likes this.

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