PO500 Code after J-Shift Transfer Case Install

I just installed a J-shift transfer case from a Tacoma or a 4Runner (which I am not sure) in my 2000 Tundra.
I made sure to remove the plug from the transfer case extension housing on the jshift and replace it with the rear output speed sensor from my stock transfer case.
After installation, and taking it on a small test drive, I got a PO500 code. The speedo and the odo were not functioning. I was suspicious that there was something different about the 2 transfer cases.

I was right!

Inside the tailshaft extension housing, there is a worm gear sleeve that slides over the output shaft on the transfer case. That gear interfaces with the sensor and communicates with the front speed sensor to tell the ECU how fast you are moving.

The OD of the sleeve from my stock transfer case measures 1.62 inches. The OD of the sleeve from the J-shift transfer case measures 1.52 inches. That .1 of an inch makes all of the difference.

Removal and installation is very simple. You need to remove the drive shaft flange, followed by the 5 12mm bolts holding the housing to the transfer case (this is sealed with RTV so it gets a bit stuck)(Pro tip: pry on the small corner next to the opening where the sensor goes into. It will pop right off). After you have the flange and the housing off, you need to remove 2 small washers. They should just slide off the shaft after you line them up with the tail shaft's grooves. A small ball that remains in the shaft stops the worm gear sleeve from spinning on the shaft. There is a groove inside the sleeve that you have to line up with that ball. The ID of the 2 worm gear sleeves are the same and therefore are interchangeable.

This is an image of the worm gear from the J-shift transfer case.

This is an image of the stock Tundra transfer case worm gear.

This is an image of the 2 gears side by side on the stock Tundra transfer case.

Hope this helps!

 

Awesome post! @BroHon and I were discussing this swap just yesterday. Thank you for the info and tutorial.

 

What engine do you have?

 

Welcome(back) to the forum! So when I was saying on the FB page that your speedo runs off the transmission, not the transfer case, you never mentioned the transfer case swap. Or I just missed it completely. Both are reasonable options.

So just thinking aloud here, if it popped a code immediately w/o you even moving the truck, did anything happen to your factory sensor? Was there any cutting/splicing involved?

 

The 4.7 2UZ

 

Thank you! I guess I should clarify. The code popped up immediately after driving. I did check the wiring, everything seemed in place.

I considered the possibility that the sensor is 25 years old and after likely not being touched since then it could have simply failed. I was a bit sticker shocked. The aftermarket sensors were $80-$100. I figured it was worth the effort to pull everything apart knowing I had a working speedometer before the swap.

 

Gotcha. Throw up a pic of the two sensors if you can. Does the connector look about the same, i.e. maybe just putting the tacoma sensor in would work?

 

Nope. 5VZ and 2UZ have different sensors with a different harness. It might be possible to swap the sensors and re-pen the harness but it might not communicate with the ECU.

 

Yup, that was gonna be my second question.