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FJ Cruiser T-Case Install in 2007 Tacoma 6-Speed Manual

Discussion in 'Garage / Workshop' started by SuthrnTaco07, Oct 13, 2011.

  1. Oct 13, 2011 at 8:58 PM
    #1
    SuthrnTaco07

    SuthrnTaco07 [OP] Well-Known Member

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    The story an explanation:
    So because all I've found is how to do twin stick conversions and what the hole looks like from the top side when these installs are finished I thought I would make a pretty informative install thread once it is finished! But for now a teaser pic and the baseline story!

    So fast forward from brand new to a little over 3 years about 60,000 - 70,000 miles later I started to off-road a good bit! The warranty was up and I had already thrown my drive train warranty out when I put my bigger tires and lift on so the heck with it! In this process I found a very weak Toyota item which through further research proved to be a common problem! The infamous 4wd actuator! This item is absolute crap and has a absolute bull crap price to go along with it! :mad:

    So in thinking of other ways to fix my problem and get my 4wd capabilities back i ran across RST (Rock Solid Toys) and there I learned the best kept not so secret of Toyota!!! The FJ Cruiser Manual Transfer case! Traditional strength and durability you would expect from a Toyota product in a modern package! :yay: It was light at the end of the tunnel! Competitive pricing with the replacement actuator (The used t-case is actually cheaper if you price the actuator through Toyota)! Then I read on... You don't have to have a crawl box to use it! It is a direct bolt up to the Tacoma transmission! :eek:

    The FAIL:
    CRITICAL UPDATE PLEASE READ:
    So for those of you planning on tackling this in the near future use my FAIL to your advantage! There are 2 types of these Transfer cases out there! They are both Manual select gearing just 2 different type drives.. 1.) Automatic Transmission 2wd/4wd select with 4wd Lo and 2
    .) Manual Transmission AWD with 4wd Lo. Out of these models the Manual T-case absolutely will not work if you plan on using it on a stock application like I am.

    Below is a Manual Transmission AWD FJ Cruiser Transfer Case \/\/\/ (This WILL NOT work in our stock application trucks! Notice the length compared to the Automatic Transmission FJ T-case below)
    DriversideFJ_fc2530ccf244f25d83a0061cae545fb10a97c1d1.jpg

    Automatic Transmission Fj Cruiser Transfer Case \/\/\/
    DSC03267800x600_461489f20c81c884e728daa3b02107c88c3c5c38.jpg

    So I did the conversion over the weekend and got tons of pics only to figure out half a mile down the road that the Manual Transmission case will not work at all! I found out by talking to Wyatt from RST and because I told him that my case seemed to be about an 1" longer towards the back then my stock and he knew right then that I had the wrong case! He is a mechanical GENIUS! He can walk me through the steps on how to do this in his sleep! He has been a great help and I've decided to do a harder mod then originally wanted.



    THE WINNING FIX!!!:

    With advise from Wyatt, he recommended that I go ahead and purchase an Automatic FJ cruiser case and swap my factory input gear set with the input gear set on the FJ case. So I talked with the local enough LKQ company in Ardmore, AL that I bought my T-case from and told him everything that has happened and told him I need a Automatic transmission T-case instead! I asked him what he could do for me and he hooked me up! He told me all I have to do is bring the one I bought back and trade it out even! He just had to order it from another shop. So I did, now for the differences!

    The main difference in the 2 is for Tacoma and FJ Cruiser Manual 6-Speed transmissions is the Input spline. The Manual has a 23 tooth and the Automatic has a 22 tooth! To swap it read below! Plenty of information to get you through this simple task!

    http://www.rocksolidtoys.com/forum/showthread.php?t=112

    My Install! (Most pics are of the wrong case but because I did the right case by myself the steps are the same!)

    FIRST:
    Drain the Transfer case completely then do work!
    To make it easier on you.. Loosen the drive shaft nuts from the transfer case. Then lift the rear end to rotate the axle and allow easier access to the flange bolts. After that proceed to take off the carrier bearing support, unplug the sensors, take off the front drive shaft shield, and then the front drive shaft flange bolts. Note: all flange nuts are 14mm and to hold the front shaft steady I used a 17mm closed wrench on the flange bolts.

    DSC_0007_a99a213d81940a8036a3aee98167d2c09c4ec841.jpg

    DSC_0006_bdc7df3cc4366376a0451035909201067c2d0ce0.jpg

    DSC_0008_6353218ad736b3a3b98f1ee2c1ad95a5c4def045.jpg

    Sensors
    DSC_0014_cc67bd36f202c3c0e17d2c0a17714df598c21ed2.jpg
    DSC_0013_ee56e9f9c1c0472bf59d69146c3c34d534693666.jpg

    Front Drive shaft flange shield
    DSC_0009_6b400326b030ee9c7bec7e3ff27b27ddf2176018.jpg

    Then once you get that completed you are ready to disconnect the transfer case! Be sure that it is in 2wd before you disconnect it! It will come in handy later! There are 8 12mm bolts holding the T-case to the transmission one of which is located directly in front of the Transmission mount. Pull that one out last! It won't fully come out but you can ease the t-case out a little to get it disconnected then drop the T-case!

    DSC_0017_3d855b15e7684bfe8eb5382da2cfc854e41e898e.jpg
    DSC_0018_11e71fad1c3b9c13bf93004e1022d9d07dde843a.jpg
    DSC_0019_e1be96bd2ed69dd885eff83585e81b2029a207bd.jpg

    The break down! (Manual Only)
    Go here for more information: http://www.rocksolidtoys.com/forum/showthread.php?t=112

    Both cases will break down the same. I'm posting Wyatt's pics because I did all of this case by myself so I didn't have time nor the energy to take pictures as I went! Most of the pictures above and below were of the original attempt. I'm stating this because it can be done solo and all with hand tools in an apartment! (That's where I did mine!)

    Open case
    tacomacase1_c2c07b241093ae22d9d5797ec57ae9b0bc3ba6a2.jpg

    Input shaft side of case
    tacomacase2_8a2449b98b25d7166ad4345bfd3402c2868985d5.jpg

    Take the oil pump guard/screen/magnet off
    tacomaoilpumpguard_1d47be823a98cd2969e51f7b0cf57f77319d2569.jpg

    Then take off the oil Pump
    tacomaoilpump_62eec16950f199c85d16c9d9fecd5bcc85ccfd87.jpg

    Once that is complete you can take the housing over the input shaft off if you haven't already done so to reveal a bunch of bearings and clips. There you will take off the clip holding it to the t-case!
    tacomagears_5bff0ccda90b155b9da6011df186a9170b919e79.jpg

    Once both gear sets are out, swap the gear set and its housing on to the FJ case and put that side back together.
    manualautogears_de498221e311c8e6ce3fb48f52441e49551a8aa0.jpg

    Twin stick mod it while you're in there for the just in case scenario!
    More info on how to do this: http://www.rocksolidtoys.com/forum/showthread.php?t=35

    Here is what mine looks like now and I am still using a Single stick for now.
    shavedfork_a1eaa950a1b2ba984e445494eb7b4bd6c65db5b0.jpg

    Then reassemble the cases... (Preferably the FJ case first so you can finish your truck) Once reassembled install the proper shift sensors in the correct side and plug the hole as shown below. According to the thread the sensor with the keyed center goes on the driver side.
    fjcasesensor_314f42d543cf9bb123f35a2cd7fa04943350ffee.jpg

    Also install your speed sensor out of your original Manual Transmission Transfer case into the plugged whole in the FJ case!
    More Info: http://www.rocksolidtoys.com/forum/showthread.php?t=164
    fjcasespeed_3178ecd5a9117e57902681eb59d78df51445238d.jpg

    Interior
    After that get to work on disassembling your center console area! Once completed assess where the hole will be cut and make sure no wires or anything important is in the way.

    DSC_0020_359ba8b3ef2aab02941b15608c159b8bbce05d9e.jpg
    DSC_0021_9fef1f8a1fe574e03194d6e9f71eb870d31abb1b.jpg

    Here I cut the carpet that was crossing to give me a better view of what I am working with! NOTE: A section of this was layered with another piece of sheet metal for some mounting brackets and was tack welded in spots. You'll have to cut that piece out also.
    DSC_0030_e5bb7227c32a47efa143e023113d1c02cae7f201.jpg

    Once cut I test fitted the T-case!
    DSC_0033_b6b9bedafe5cf9dbe6090d6bf5db2f8165c92c8a.jpg
    DSC_0032_1250ca4e8dd8161424187cd69d7bfba46a43b9bb.jpg

    Then I installed some rubber flashing for the shifter to move freely!
    [​IMG]
    [​IMG]

    Under the truck view
    [​IMG]

    Once you are happy with the install reassemble the truck and fill it with oil (80w-90 Almost 2 Quarts) and you are almost done!
    [​IMG]
    Product placement!! ^^^^

    I'm sure you were wondering how are you going to get your 4wd lights to work again... Well the answer is behind the glove box. Follow the instructions on the bottom of this thread: http://www.rocksolidtoys.com/forum/showthread.php?t=60

    Also after this towards the end of the month check back for more on the Twin Stick conversion of my T-case and my version of the install! Thank you for checking it out.. Sub for updates to come!
     
    DistortedAxis likes this.
  2. Oct 13, 2011 at 8:58 PM
    #2
    SuthrnTaco07

    SuthrnTaco07 [OP] Well-Known Member

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    Finally Updating what the final look of my twinstick conversion

     
    Last edited: Oct 5, 2016
  3. Oct 13, 2011 at 9:05 PM
    #3
    tinker_troy

    tinker_troy VAN ENTHUSIAST

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    oooooh yes please
    :popcorn:
     
  4. Oct 17, 2011 at 3:57 PM
    #4
    awsumdc

    awsumdc Well-Known Member Vendor

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    Thanks for the compliments Kyle. Your issue is the exact reason I started RST.

    You can call me anytime you need help on your install and conversion. You know if I don't answer right away I will get back to you. ;)
     
  5. Oct 17, 2011 at 5:07 PM
    #5
    SuthrnTaco07

    SuthrnTaco07 [OP] Well-Known Member

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    I know it! You are the best! How did the tournament go? Thank you again for making some time for me!
     
  6. Oct 17, 2011 at 6:54 PM
    #6
    SpazzyB

    SpazzyB Master of the Prius...

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    sad day. :[
     
  7. Oct 17, 2011 at 7:01 PM
    #7
    Warhorseforever

    Warhorseforever Will The Thrill

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    Sub'd just because I want to see this.
     
  8. Oct 17, 2011 at 7:07 PM
    #8
    FlawedXJ

    FlawedXJ mall crawlin', web wheelin', concrete cowboy

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    I actually have a jeep now. Imagine that.
    sub'd because I have a feeling I'm going to be working on this :D
     
  9. Oct 17, 2011 at 7:31 PM
    #9
    SuthrnTaco07

    SuthrnTaco07 [OP] Well-Known Member

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    MAYBE!!! I might be done by the time you get here! LOL! It looks like i'm going at it by myself tomorrow! LOL! But will be getting the right case this time!
     
  10. Oct 17, 2011 at 9:33 PM
    #10
    awsumdc

    awsumdc Well-Known Member Vendor

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    Not really. It's been a good experience for Kyle. Because of his small "commercial break", others will bennefit.
     
  11. Oct 17, 2011 at 10:26 PM
    #11
    SuthrnTaco07

    SuthrnTaco07 [OP] Well-Known Member

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    Break is key there! Hopefully tomorrow goes well and I get to get my new T-case from them for an even swap!
     
  12. Oct 20, 2011 at 6:56 PM
    #12
    awsumdc

    awsumdc Well-Known Member Vendor

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    Any updates yet?;)
     
  13. Oct 20, 2011 at 8:16 PM
    #13
    SuthrnTaco07

    SuthrnTaco07 [OP] Well-Known Member

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    When I get home... Lets just say I stayed up till 4:30 in the morning swapping internals out! I was just trying to get it done right!

    Note to anyone else attempting this mod! Be sure to have air powered or 120v powered tools! Hand tools BLOW!! I did all of this by hand and the 2nd attempt by myself so i quadrupled the time it took! BUT! All that was left before I went to work today was to pump some fluid in and connect the rear drive shaft..

    Hey Wyatt.. So i noticed the speedo was mounted on the rear the rear flange of our stock case... Where is the one for the FJ's located?
     
  14. Oct 20, 2011 at 8:20 PM
    #14
    jonny

    jonny Betty White Edition Heep ZJ

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    I have a manual transfer case :anonymous:

    :laugh:
     
  15. Oct 20, 2011 at 8:45 PM
    #15
    SuthrnTaco07

    SuthrnTaco07 [OP] Well-Known Member

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    Not anymore.. I stole it from you! :eek:
     
  16. Oct 20, 2011 at 10:38 PM
    #16
    squamish VFR

    squamish VFR Well-Known Member

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    :popcorn::popcorn::popcorn:

    I'm very curious about the single stick treatment/options...

    I don't need the twin sticks really; I can't think of a time I need 2wd low range. I'm not hard-core like some of you guys. I just want a truck that I can rely on, and while I'm pissed at having to fix a problem that should never have been I'm grateful that a solution was found and people like yourselves are willing to pass on that knowledge.

    Edit:
    Oh another question, when you swapped the input gear set did you swap the outer gear from housing to housing or are they the same?


    Now if only I could find a solution to the manual trans engine fuel mapping issues...uhg!
     
  17. Oct 21, 2011 at 1:35 AM
    #17
    Trapper6speed

    Trapper6speed Hacksaw engineer

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    I want 2wd low.
     
  18. Oct 21, 2011 at 5:04 AM
    #18
    awsumdc

    awsumdc Well-Known Member Vendor

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    It's in the same location on the FJ case. You just need to remove the plug that is there on the FJ case and put your input gear there and plug it in. :p

    Here is a link to how I did mine on my Tacoma since when I swapped my rear axle I lost my speedo. http://www.rocksolidtoys.com/forum/showthread.php?t=164
     
  19. Oct 21, 2011 at 5:11 AM
    #19
    awsumdc

    awsumdc Well-Known Member Vendor

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    I had the single stick on my FJ case when I first swapped it in and it worked perfect. But when I swapped to twin sticks, a whole new world arrived baby!!:D

     
  20. Oct 21, 2011 at 5:12 AM
    #20
    awsumdc

    awsumdc Well-Known Member Vendor

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    The outer gear is the same and does not need to be taken out. To get it out is a pain anyway.


     
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