R150F 5 speed transmission and "push button" electronic T-Case replacement options?????

So my 2002 TRD 3.4L 5 speed is closing in on 400k miles and the O.G push button transfer case leaks like crazy (works fine) and my Marlin crawler R150F 5 speed (replaced by previous owner at 250k) also leaks and is not happy (3rd and reverse notchy to get into, famous whine). ***Yes, the complete clutch, flywheel, throwout bearing and master/ slave cylinders were all replaced with factory AISIN units 40-50k miles ago.

I've been having a hard time trying to find a used "unicorn" push-button T-case and/ or deciding on rebuilding/ resealing what I got? Anyone been through the rebuild? kit cost? extra parts needed "while in there"? special tools (other than a press)?

as for the R150F I don't trust the current trans or Marlin crawlers rebuild which lasted less than 100k miles before leaking/ whining. I see Yota1 offers a R150F for $1700 + $500 core (1 year warranty). And my local Autozone also offers a rebuilt unit for $1600 + $400 core (2 year warranty). Does anyone else offer quality rebuilt units?

can I use R150F's and push-button T-Cases out of 4runners or other year/ gen tacos? I've read about the different input shaft length on the trans but are there other non compatible issues? Would a J-Shift T-Case bolt up to my stock driveline/ R150F and work other than loosing the push-button deal?

Thanks for any input!

 

For the transfer case, @turbodb has a very thorough writeup (https://adventuretaco.com/guide/step-by-step-replacing-the-transfer-case-on-a-tacoma/) and related discussion thread (https://www.tacomaworld.com/threads/1st-gen-transfer-case-identifcation-for-replacement-swap.753707/) on the different variants and compatibility between them.

 

Why not rebuild both units? If the t-case is just leaking, but otherwise operates fine, it probably just needs input/output shaft seals and/or flange seals.

The r150 can be rebuilt by a competent shop for ~$1000, including all new seals and bearings. If there is any damage or wear to the gears or synchros, they can replace those all with little trouble.

You could source a new/used t-case, it would need to be a push button with the same “options” as yours (4lo and neutral switches for ABS and e-locker functionality). Those switches can be added later if necessary. You can use a push button case from either a r150f or an A340, the only physical difference is the input shaft is 1/2” shorter on the A340 version. If you not pushing big tires and high horsepower, it’s not a problem.

Switching to a j-shift t-case is quite a bit more involved, the 4wd ECM needs to be replaced and rewired with a control relay.

 

If you end up going through with a J-shift case swap, I think you won't regret the final product. I own a 3rd gen 4runner with the push button case (auto trans) and an 03 Tacoma with the J-shift, and the J-shift is so much better when you're going in and out of 4wd frequently.

But sounds like fixing your current case is certainly the easier route.