Convert Transfer Case to Manual Levers

So, has anyone ever made a kit to remove to electric controls on transfer case and switch it to manual levers?

 

https://www.google.com/search?q=sit...dcBiAHKFJIBBjEuMTguMZgBAKABAcgBCMABAQ&sclient

 

People have done it on a 2nd gen by either swapping the transfer case or upconverting a 2WD with a donor FJ cruiser.


I'm not sure of a successful 3rd gen example though. The electronics are... Finicky.

 

Why. I've had both and a dial is much much better. If you want a lot of maintenance and upkeep then keep up this dream.
The guys who build the buggies and heavy off road trucks use manual levers because it's easiest, not because it's better. Plus they are using doublers and other stuff that would be a nightmare to electrify.

 

Having manual control is only part of the problem. I don't believe the FJ case gives you lower gearing and that is what we need.

 

I’ve also had both. I’m not anti technology at all but I can’t think of one single benefit to choosing the knob. Even if I could think of one, I could think of far more benefits to the lever.

 

I’m curious what the numbers are. I’ve seen a lot of broken actuator posts on this site, and the electronics really aren’t that complicated.

 

Solenoids take the place of manual detents. There is really no advantage either way. I have had problems with both ways.

 

Troubleshooting is easier with manual. That's it.

 

Solenoids seem to add potential failure points in that they require more seals, where as a manual case has one big seal on the top. Most of the fails I’ve seen are with water/mud intrusion to those solenoids.

 

You mean when they are finicky and don't want to go into 4wd because everything isn't perfect and under no tension to allow the electronic actuators to work correctly and the manual you can grab and give a little stronger jerk and it goes into 4wd isn't a good reason? Yeah, that is a good run on sentence. The issue rears its head if you end up in a situation where you have to put it into 4wd to get unstuck/out of your situation. I had this happen in a Ranger and was not fun. I would take a second lever in the cab any day.

 

Until you have a second lever that wears out and vibrates and won't go into gear. There are advantages and there are disadvantages. You gotta live both.

 

Never experienced that let alone heard of that except in old 70's Chevy trucks, but they still worked.

 

Jeeps. Enough said. Chevys too. Lived the dream both ways. I really see no advantage either way.

 

I don’t think either way is perfect but the physical shifter is far less likely to fail. And if it does, it’s usually a simple/cheap mechanical fix whereas with the fancy knob setup, you’re usually looking at a pricey control module or actuator. I don’t hate the knob in normal operation but when it fails, it’s a bad day. I also like that you get neutral with physical shifting cases.

At the end of the day both do (mostly) work fine though.

only issues I’ve seen on Jeeps is where the folks install a body lift which tweaks the linkage into not working. A cable shifter solves that for good. Never seen issues once a cable is in and working.

 

I have never met a 2nd or 3rd gen Tacoma that wasn't finicky to engage 4HI and 4LO. Once my 2nd gen got stuck in 4LO, only had 48,000 miles on it at the time, and I fought with it for an hour until it finally went back into high range. Of course I was 250 miles from home and out of cell range. I was about to kick the stupid plastic actuator motor off the T-case and try to pull the linkage out with a pair of channel locks. I thought it was just my 2nd gen until I spent time in others. Then I thought it was just a 2nd gen thing but my friend's 3rd gen he bought new is the same way. My first gen with the superior manual lever instantly engaged and disengaged every time. I've had several company Ford and Chevy full size pickups with electronic transfer cases, all of them worked quickly and flawlessly. Now I'm on the hunt for a new camping and off-roading truck, it was about to be a Heep Wrangler but I think I've come to my senses and I'm going to get an FJ Cruiser, the last Toyota 4X4 sold in the US with a manual transmission and manual transfer case.

 

I don't think you understand how 'levers' work. There's nothing to wear out or fail (with exception of a shift bushing)

Having a purely mechanical way of moving the shift forks in the transfer case is always better than relying on a electronic way to do so.

 

Lol I had to tie my Jeep shifter to the dash with a string to keep it in 4wd so I beg to differ.
You make the statement above that it is always better to have a mechanical interface. Why then, does just about every single auto manufacturer in the world use electronic controls for 4wd?
Last one I had with two levers was a 4runner and it was just as much a pain in the ass to shift it as the old Jeeps were.
I get the simplicity aspect for sure, but why make one thing simpler on a vehicle full of complexity? If we followed that logic we could go back to carburators instead of fuel injection, 8 track tape players instead of Spotify and... since this is a lever thread, let's go back to the days of vehicle HVAC operated by levers! And... Headlight dimmers that were a click button on the floor! And more levers... A manual choke! And let's get rid of automatics and make the Tacoma great by only offering manual transmissions!

I say all this tongue in cheek but levers?
Solenoids and electric motors last an awfully long time and work really well.

 

To save space in the console? Or, because that's what most consumers (not enthusiasts) want?

What year 4Runner? Mine's totally smooth at nearly 90K miles, as was the lever in my '94 with ~220K when I traded it in.

I haven't noticed any threads about lever operated transfer cases failing to engage or disengage 4wd. However, I've heard of electronic actuators failing. I'd be more concerned about the actuator in my front differential failing than my transfer case.

That said, the actuator failures are rare and usually seem to be caused by a lack of maintenance or exercise.

I definitely don't think it's worth switching to a lever just for the sake of switching to a lever. But, given the choice, I'll take a lever.

 

I have both now. I prefer the 02 with levers way way way better than the 20 with its stupid knob. Entering 4WD on the 02 is instant and the 20 is hit or miss. And the 02 has 506K miles and it has never never had a problem with 4WD.