Prerunning in 4WD (Yet another 4x4 swap...)

Sae68 · Oct 3, 2017

Thank for sharing. Can't wait to start my conversion.

adamw · Oct 3, 2017

I am happy to share what I learned. I think it is a unique project that many people don’t feel like taking on

adamw · Oct 3, 2017

UPDATE:
finally got the exhaust rerouted, and the shifters cut/welded. I ended up burning out the rubber isolator for the trans shifter to shorten it. Then I poured in epoxy to bond the inner/outer shafts.

bfogelma · Mar 17, 2018

adamw[OP] said: ↑

Finished up the transfer case the other night. It was pretty cool taking it apart and seeing how everything worked

Thats the shaft that needs to live inside the tcase

Manual v auto input shafts

input shaft cover and front pinion flange were the first things which needed to come off

split the case to get to the oil pump and planetary gear set

oil pump out

gear set finally removed along with both input shafts

operating room aka washing machine..

All buttoned up, the huge snap rings suck if you dont have the right pliers, which I didn't..

getting everything ready on the side of the case, I ended up greasing the 3 little keys which the 4x4 engagement gear slides over otherwise there was no way they were going to hold themselves in there while sliding the big ring gear over them and putting the cases back together

final test fit/sanity check. everything ended up going back together and shifted smooth and buttery thru the 2wd,4wd,4lo. the levers contact each other in a few positions so I will need to address that. in 2wd I wont be able to get into 5th or 6th. I have a URD short shifter on the way but im going to have the cut the t case shifter to angle it more passenger and potentially forward depending on how it looks when its bolted up to the truck.
Click to expand...

Was this done to swap from a manual input shaft to auto input shaft?

adamw · Mar 18, 2018

bfogelma said: ↑

Was this done to swap from a manual input shaft to auto input shaft?
Click to expand...

This was done with a tcase from an auto fj into a manual tacoma

adamw · Mar 27, 2018

Also finally was able to install my custom shit boot which I had made, looks OEM now

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