Betterbuckleup's 2000 taco build & BS

Yea I think the rear adapter I have is the same pattern as the one you have on the right. So it must be for an 05+ tacoma.....awesome.

I haven't gotten the front adapter plate off yet. I'll need to when I get the correct adapters, but I plan on using those bottom two screws in addition to a rubber mallet on each corner. Maybe some heat too. I'll let you know. Hopefully it isn't too much of a pain to get off.

 

Ya I ended up grinding it flat like you said just in case. Don't wanna have to get back into it to fix it down the line.

The marlin adapter showed up today so i'll know if that's gonna work any better here shortly when I test fit it. But yea I needed a BFH to get it on. Should have tried popping it in the oven beforehand to get it on there easier. Oh well.

Interesting. I know that's the case with inchworm, but it's def not the case with this TG adapter. There's holes in places there shouldn't be and visa versa.

 

So I went and grabbed the damaged adapter that they first sent me.
And sure enough when I brought it home and checked it against the "replacement" one they sent, it was different
I tested the original and it fits like it should on my factory case.

I feel kinda dumb that I didn't notice this before hand when building it up, but I mean I shouldn't have to check for this kind of shit to begin with.




On the other hand, I got the marlin coupler and it should work perfectly with the TG adapters. It's the same length and OD as the TG one. You can see that the splines on the marlin coupler on the input side are a big shorter in height than the TG ones.

It slides right onto the marlin input gear splines like butter. Way easier than the TG one, so I'm happy with that. Still have to clean off all the wax coating from it though.


marlin on the left and TG on the right


I also checked the front plate adapter just to be sure there wasn't some hokey shit going on there too. But thankfully that matched up just fine with the transmission. So shouldn't be any issue there.

Wonder how tf TG managed to get a second gen rear adapter mixed in with a 4cyl first gen tacoma adapter kit.

 

So rather than wait for TG to get off their ass and send me the right adapter, I figured I'd just try and fix the first adapter they sent and make it work. Tear it all back apart and build it up again with the other adapter.
Took my dremel and sanded down the part that got dented, and then drilled out the hole so it would accept a bolt. Should be good to go. Or at least i'll find out when I go to fill it all up.



Separating the rear adapter was tricky. Ended up putting another nut behind one of the studs and used it as a jacking screw against the adapter to push the other T-case away from the mating surface. Worked pretty well.


Bolted everything together with ultra grey and waited an hour before torquing to spec. Interestingly my chain case already had the 11mm dowels in it. TG instructions tell you to install the ones they provide. Wonder if the v6 one doesn't have them or something.




Really hope this thing doesn't leak because it's heavy as fuck and annoying to muscle around on the tranny jack to get it to line up.


Cut holes in the floorboard last night for the shift linkage.


Also extended the 4wd switch wiring. Will also need to extend the wiring for the speedo sensor on the back of the case.


Installed the coupler into the trans too. Used a metal 5 lb sledge this time to drive it in. Idk why it's such a tight fit with my 4cyl 26 spline shit but it's in there now. Will put the seal extension housing on there after I dry fit it up and make sure clearances are all good.

 

Since you're diy to the bone I'd say making jacking plates that you could bolt to the pieces of the transfer case etc. and remove one section at a time could possibly be worth your while - I know you'd have to take a good amount of time tracing out mounting holes, but something I've seen on here for other things...

 

Not a bad idea. although the methods I used worked pretty well. So if I were to pull it apart again, I would probably just use the same method.

for the front plate, there are two mounting screws at the bottom that I just threaded bolts into that acted as jacking screws to push The adapter plate off of the front of the transfer case.
You don't need much force, just really enough to break the seal of the silicone. Then the rest of it comes off pretty easy.

 

Last night I got the seal extension installed and the cases bolted up to the transmission.



I put blue loc-tite on the seal extension mating surface and then put some silicone over the edge after it was installed just for good measure. Even if there's a leak and the transmission and crawlbox end up sharing fluids, it's the same stuff in both so it's not the end of the world.



Had to open the floor some more to make more room for the shifter linkage.


Tonight I'm gonna fill up the cases with gear oil and check for leaks and then hopefully run the engine and make sure everything shifts and spins like it should.

I dropped my driveshafts off yesterday morning, so I should have those back next Wednesday or Thursday. Making some good progress!

 

@betterbuckleup how do you like the transmission jack so far?

 

I have that one and if you're doing one component at a time it's not bad. Unfortunately there's a ton of wiggle in the adjusters since the tolerances are so loose. I had a tough time getting the 4x4 trans and transfer case lined up with the engine but it was at the end of an all nighter.

 

It does the job. Nothing crazy nice.
When I did my clutch before, I had the HF 1500lb one (or whatever capacity their biggest one is). This one is better because it's smaller. It's the 800lb one. The bigger one is much heavier so more of a bear to move around.

If I were to remove the transmission and leave the crawlbox and t-case attached to it, I would prob want the bigger one because this shit is heavy AF now. Would want the stability with maneuvering a long unit like this.

Yea I would agree. Although it's usually a pita to get shit like that lined up regardless of the jack you have imo. It took me a while to get the splines to line up with the coupler on the crawlbox. Patience definitely helps lol

 

Been considering making one of these with my spare transmission as a jig:



https://www.tacomaworld.com/threads...ur-5vz-clutch-trans-job.501273/#post-15609683

 

I like that idea. Would def make moving the trans around a lot easier.

Would have to figure out a way to make it removable with a HF jack though.
I have this one and it's been great for all my needs

 

The Race Jacks are mod-able - could just be another extension if you have one as a trail jack.




https://www.tacomaworld.com/threads/taco-sauce-tx-pro-basic-build.215653/page-26#post-22352322

 

Hmm interesting.
yea maybe down the line if I feel the need. But for now I'll just keep endangering my life with my hi-lift on the trail lol

 

I've been up to my ears in higher priority things including other truck projects, but I've got the yellow version of the Daytona jack and if it's like the race jack I'll mention it in here.

 

Cool yea if you're able to make something work with that one, lemme know. Not that my project list isn't long enough already too....

 

Killer progress man, glad you got the adaptor issue sorted and everything together!

As I was reading through and looking at pictures, and returning the nightmare that was doing it without a transmission jack.. it got me to wondering..

One thing that REALLY sucked, most likely because I didn’t have a transmission jack and was making things work with ratchet straps, was getting the FIPG on between the trans and the boxes. I had to pretty much get everything lined up and close to begin with since I was basically bench pressing things into place, which meant I had VERY little room to apply the FIPG. Looking at it all again through your pictures.. I wonder how an actual gasket would work if you stenciled one out? If I have bad leaks when I fill it up and fire the rig up I may guinea pig a stenciled gasket, would make tear downs a helluva lot easier.

Keep up the good work!

 

Yea I kinda wonder the same thing. I think that the silicone is better because it'll be able to fill in small imperfections in the surfaces of either side where as a paper gasket wouldn't be able to as well. But it does have it's downsides. Since I've been doing this after work mostly, I've been letting the silicone cure fully before getting all handsy with it so that it doesn't smear everywhere. Fingers crossed I don't have leaks when I fill it up tonight or that I have to pull it back off for whatever reason.

But yea gaskets would def make serviceability and cleanliness a hell of a lot better! Maybe you trace out a gasket, but make it out of some kind of rubber material that'll seal better? Something like Fel-Pro gaskets have.

 

Maybe something similar to this:

Silicone Sheet Gasket, Red

https://www.amazon.com/Small-Parts-Silicone-Sheet-Gasket/dp/B0075ZMUOC

 

Yea something like that forsure. I'd probably want something a bit thinner, but then again I have no idea about a "gasket spec" for stuff like this lol