Hey guys, I知 fact finding on 4th gens. I originally wanted a 3rd gen. but I知 trying to stretch my budget out to a 4th gen.

The question I have is what is the longevity of the V8 transfer cases vs the v6 models? (V8 is full time 4x4, v6 is not)

I値l really only be able to afford something 250 mile+ range, so I知 worried that the V8 transfer case will be as tired as the trans. Could be a rebuild cost I can稚 really afford to gamble on

So, I bought my 2003 with 280k miles on it. The trans is fine but the tcase actuators are crap. Unless the PO used 4wd on a regular basis, you are likely to have issues.

The best fix for the tcase is to do an FJ Cruiser tcase swap. That's what I have done on mine. Manual tcase, no electronic crap to fail.

Change fluids with the correct stuff as soon as you get the vehicle and you should be fine. Be sure to carefully check the tcase operation BEFORE you buy. The tcase won't fail mechanically, just the shitty electronic motors. And then it's pricey to get fixed and not easy. FJ swap is cheaper, especially if you do the work yourself. And bulletproof.

Thanks, how involved is an FJ Tcase swap?
How is the 4hi -4low actuated then? The old style shift lever inside the cab? If so, does it look like a factory option?

They are fine. You have a better chance of winning the lottery than breaking one.

Only time I have seen a t-case break is when rock crawling all 4 35" tires were hopping under a good amount of throttle and created a hairline crack on the case near the output shaft after a loud crack.

The actuator is the only thing that really gives anyone problems.

Aside from actuator failure the only issue I've heard of is from ignoring a bad u-joint. Seems the position of the one near the t-case can damage the t-case housing if it fails.

Thanks guys, I don稚 really know much about transfer cases. I知 more concerned about wear and tear than breakage. In the snowbelt areas I assumed v6 transfer cases only see powered use in poor weather. But the V8 transfer case has same miles as the driveline.

The main thing is does it work when you buy it. If you can exercise it several times and it works, then by doing your monthly "use it or lose it" you are probably going to be more or less fine.

That said, the actuator is the weak point. If it is seized, there is a thread on this forum somewhere with how to tear down the TCase to replace the seals, etc. However, if the motor is toast, there isn't much you can do short of buying a new actuator. RockAuto has an Dorman one for 700$, and they go up from there.

This is why I push the FJ tcase swap.

$200 - $250 for a manually shifted FJ tcase from an automatic (NOT the manual trans FJ, won't fit).

Around $600-$700 for the modified driveshafts, new. If you can find a shop to shorten/lengthen, it'll be cheaper.

If you do the work yourself, it's an easy swap. Cut a hole in the trans tunnel, cut and weld or have welded the shifter handle to come up thru the ash tray. Measure and have modified the driveshafts.

If you have a V6 with ADD front axle, you need to make a wiring harness to manually activate the ADD or just lock it permanently. The V8 models don't require this.

That's all there is to it. It's really that simple.

Repairing the stock tcase actuators will cost a lot more in the long run and have the potential to fail again. It just wasn't worth the cost or effort to me when the FJ tcase swap is so easy, much cheaper and vastly more reliable over the long run. And I now have 2wd in my 2003 V8 4Runner.

This sounds really cool. Any fuel mileage savings in 2wd? I値l be doing a lot of travelling in the summer/fall

AISIN SAT-003 is the original actuator, they're around $500.

The actual Tcase is easy to source, it's the same unit for all 03+ 4runners and Lexus GX's.

Not that I have noticed. It really hasn't changed any.

How does 2WD affect traction control and VSC?

So basically I need an FJ TCase *AND* an FJ rear axle now xD

In all seriousness, one of the reasons I went with a 4th gen over an FJ or a 5th gen was the multi-mode transfer case. We use ours as our all conquering snow vehicle as well, so having AWD is nice.

Still, cool mod.

It doesn't. Still works the same. Completely different system, unrelated to 2wd or 4wd.

4HI is the same as AWD, just minus the center diff. If you are in snow or mud, you don't want or need that center diff most times anyhow. 4HI can be engaged while moving, up to like 25 or 30mph, by pulling the shift stick straight back. Simple. One extra step for a V6 is to engage the front ADD, unless it's been locked in permanently.