Manual transfer case swap

Here’s a rundown of how I installed a 1997 4Runner transfer case in my 2006 tundra. I did this because I couldn’t get 4low to work reliably after my straight axe swap. I know this has been done before with the better fj transfer case but 4Runners are much more common in my local salvage yards because of this my total cost for this swap is just under $200.

 

Once the old case has been remove pull out the rear transmission seal and replace it with this one because the 4Runner uses the same 21 spline coupler but the outside of the seal area on the shaft is smaller

 

Once the seal has been replaced and a hole has been cut in the floor the case will fit on the alignment pins and bolt up with the exception of two bolts. The bottom passenger side of the case is shaped different leaving a gap on one side. I plan on making a 1/4” aluminum filler and tig welding it to the side of the case so I can get all the bolts installed.

 

I cut the shifter lever right in the lowest bend and extended it 3 1/2” forward so I can use a 2001 sequoia shifter boot in my factory console for a more stock look.

 

This is bad a$$! Nice job! I wish they all came like that!

 

This is great, well done, and great timing . I have just started to research this myself to do on my 2015. This may be a stupid question but does your front driveshaft spin all the time after this swap or do you have locking hubs or something like that? I still have my independent front but I want to get rid of the ADD (I thinks it's called) so from what I can tell my only option is to lock it in the permanently engaged position and have it free spin. I don't know if that's good for me since I live in Houston and drive on the freeway.

 

Thanks, no my front driveshaft doesn’t spin unless I put it in 4 hi or 4 low and I do have locking hubs to help with street driving since I have a limited slip front end.

 

Thanks. Awesome job.

 

Very neat!

 

Thanks for clearing that up. Anyone have any idea how I can do this without locking hubs? I will have an air locker soon but it's still an open diff when not engaged so is my driveshaft spinning from wheels turning an issue if I drive up to 90 mph?

 

The front has an axle disconnect already. No issues running it like that.

 

Yeah. Our front 4wd drive shaft spins freely (if you go underneath and check it out) without the 4wd engaged.

In other words you can spin the shaft with your hand. Its not engaged during normal 2wd driving. I assume it does not spin until engaged in 4wd.

 

Right, it has the ADD that right now gets it's signal I believe from the electronic tcase so when I put it in 4wd it engages and the front drive shaft and the front diff are then connected, but I want to get rid of all electronics associated with the tcase and I read you can lock the ADD in place but that would make the front driveshaft spin from the front wheels spinning even in 2wd. Is that correct or am I missing something?

 

Yes if you lock the add the drive shaft would spin. Have you considered leaving the add and putting it on a switch, so you could lock/unlock the front axle on command if you did this it would basically function like a twin stick and give you a 2wd low option and allow you unlock the fronend quickly for tight turns on the trail.

 

That's correct. However even if you permanently engage the front axle it'll still be fine. Some other manufacturers have had no disconnect besides the transfer case for years.

You'll get some drag but nothing noticeable.

 

I’m not sure. Go by what ethan and fester say. All I know is I like pushing a button and going right into 4hi. A quick push and I’m right back in 2wd for turns.

What is your goal? Just to eliminate the electronics in case of (potential) future failure? Everything works fine currently?

 

in manual case with locked hubs, (such as in my 1996 tacoma) is able to shift on the fly as well, it's just with a lever rather than a button.

 

I want a solid axle swap and manual t case swap super bad. Just my tundra my daily for right now and finances r a lil tight.


U got a build thread on you SAD? Or your filler for the case swap?
If I ever do it ill just copy you1

 

My sas is in my build thread. I’m making the filler at work this week I’ll put some pics on here when I get it done.

 

Awesome! After this I'm gonna need you to swap in a manual trans and post a write up on it.

 

We can dream right?

 

Everything works "fine" now. I had an issue where if I don't use it in 2 months or more, it "sticks" 9r something but after using it a few times it works fine again.

My issue came when I was at an offroad park and I was driving through some water a few times and ended up getting water in my speed sensor wiring or something like that and once there is some kind of fault, the truck locks you out of everything except the ability to go forward or backwards. I'm sitting in knee deep mud and it decided to turn off 4wd on me because a speed sensor has some water on it? So yea, decided that was unacceptable and want to do everything I can manual

 

Would this process work with a Multi-Mode transfer case from a 3rd Gen 4Runner? (the ones that have a diff in the transfer case that can be electrically locked/unlocked?)

 

I’m not sure on that one but if it’s from a 3.4 I wouldn’t be surprised if it would work.

 

Yes, they're in the 3.4. Hmmm... may have to investigate further. The AWD option in my 4Runner was nice in mixed weather.