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1st Gen AT 6 cyl original J-shift Transfer Case Owners - Output Shaft Pic?

Discussion in '1st Gen. Tacomas (1995-2004)' started by Area51Runner, Aug 5, 2022 at 7:57 PM.

  1. Aug 5, 2022 at 7:57 PM
    #1
    Area51Runner

    Area51Runner [OP] Well-Known Member

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    Any 95-00 owners have pictures of the output shaft or pictures of the internals of their transfer case? I'm trying to confirm a synchronizer ring is only present on ADD cases.

    Basically, from what I can see in TIS (looking at every year from 95-00 and even up to 04), the output shaft in the transfer case does not have a synchronizer ring nor shift keys on the non-ADD cases. They are only present on the ADD cases.

    I know that on occasion factory service data can be in error (rare, but it happens) so I wanted to see if any of you 1st gen original factory J-shift cases had some pics of the internals. Perhaps you changed a bearing and took a few pics.

    According to toyota --

    On the ADD cases, highlighted in yellow -

    upload_2022-8-5_19-36-39.jpg

    On non-ADD cases from 95-04, the synchronizer ring and shifting keys are not shown (same illustration appears for each year in that range).

    upload_2022-8-5_19-38-24.jpg

    upload_2022-8-5_20-53-59.jpg

    The synchronizer ring is brass and would be clearly visible.
    upload_2022-8-5_19-40-24.jpg

    upload_2022-8-5_19-42-58.jpg

    If you do have pics, could you post here along with specs? Again, looking for factory J-shift tcases. Thanks!
     
    Last edited: Aug 7, 2022 at 10:44 AM
  2. Aug 5, 2022 at 8:58 PM
    #2
    Area51Runner

    Area51Runner [OP] Well-Known Member

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    More background as to why this has me so curious, the transfer case I picked up from a salvage dealer on ebay is a non-add case. The area where the hole for the ADD Actuator shift fork would be was not punched out. The confusing part is the output shaft has a synchronizer ring, retainers and shifting keys. According to toyota, it shouldn't. So either the factory service data (illustrations) is incorrect or the salvage dealer pieced together a transfer case and sent it on its merry way with a VIN# for a 95 taco without AD. Either wouldn't surprise me.

    Its also not for a MT since there are no retainers or shift keys for the high/low clutch sleeve. Unless the salvage dealer decided those weren't necessary hahaha
     
  3. Aug 6, 2022 at 1:05 PM
    #3
    Area51Runner

    Area51Runner [OP] Well-Known Member

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    So the issue I have been working on with this case is the synchronizer ring has been binding to the gear cone. No matter what I have tried, the result is the same. The front companion flange will turn even though it is in 2H. You can hold it in place but the input shaft is very difficult to turn because of that binding. I've replaced the synchronizer ring and I've tried polishing up any micro abrasions on the gear cone (400/1500#). No joy.

    When I came across the TIS illustrations for the transfer case's output shaft and noticed the lack of a synchronizer ring on the non-ADD MT illustrations, I started to wonder.

    I pulled the synchronizer ring and reassembled the output shaft and slapped it back together.
    Result: case shifts fine, no binding at all. When in 2H, output shaft spins nice and smooth with ZERO movement of the front companion flange.

    Is the synchronizer ring and keys supposed to be there on all iterations or just on the non-ADD MT cases? I truly have no idea. The factory service data could be incorrect, wouldn't be the first time. This particular case I have here was supposedly off a 1995 Tacoma (non-ADD 6 cyl AT). Was it? My guess is NO.

    I am still looking for pics to try and confirm the sync ring was indeed left out on non-ADD AT cases but for now I'm going to just FIPG this thing and call it good. I'll just play it safe and toss the truck into N before shifting into 4WD. If the case ends up fragging itself over time, so be it.

    I've had just about enough of transfer cases, shifting keys and synchronizer rings.


    upload_2022-8-6_12-52-58.jpg

    upload_2022-8-6_12-53-30.jpg
     
    mechanicjon likes this.
  4. Aug 7, 2022 at 3:31 AM
    #4
    mechanicjon

    mechanicjon They call me "Jonny Stubs"

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    The repair manual shows the same thing.
     
    Area51Runner [OP] likes this.

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