Been doing a lot of reading and learning over the last few weeks.

I see some reviews knocking the 5th gen for its "manual transfer case" on the part-time 4WD models. I'm not sure what they mean by that? Is it that with the lever you're physically/mechanically engaging the transfer case instead of a button that does it electronically? Or do they mean something else?

And can you tell me anything else interesting or notable about the transfer case on these? Are they chain driven? Gear driven? Especially reliable?

Thanks very much in advance!

Yes, the "manual transfer case" is in reference to the models with the lever. Pretty sure just the TRD models have it and the SR5 gets a selector knob. If anyone is knocking it I would guess it's generic automotive reviewers because I was under the impression that the forum members and other enthusiasts liked and preferred the manual transfer case. I do anyway.

The biggest difference is the limited is all time AWD, aka it has a center diff from my understanding. the SR5/TRD are either 2WD or 4WD.

I bought my 4Runner when I was still living in Minnesota (knew the move to Colorado would happen, just didn't realize I would wheel as much as i do). Part of the appeal for a TRD OR was the manual transfer case. I've had good and bad luck with the electronic shift in my old trucks, nothing beat the reliability of my 94 suburban with a big ole floor lever.

I will say though, the auto switch in my 16' GMC was pretty awesome - you could get the benefits of a limited eq. transfer case for daily driving in wet conditions on the fly, worked really well too!

Yeah, thanks, I don't care a ton, but have zero issues w the manual engagement, one less thing to go wrong.

I've had no problems with my SR5 which has a selector knob, nor have I heard of any issues with the 4Runner transfer case. The TRD 4Runner does have the selector lever, but it is my understanding that the inner workings of the transfer case are the same. Personally, I like the selector knob for it is easier to use when switching from two wheel drive to high range four wheel drive on the fly. With either system, to go to four low requires you to come to a complete stop, apply the brakes and put the transmission into neutral, so there is no advantage of one over the other then.

It's a chain driven case. Most if not all modern vehicles on the road are because it's cheaper.

Correct me if I'm wrong, but regardless of whether you have the dial or lever, it's still just an electronically actuated T-case, no? It's not as though the lever shifter actually has mechanical linkage into the T-case to change anything?
Heck, you speak of your 94 Burb, I had a 93 Yukon, with a floor shifter, and it was electronically actuated. I had to replace it.

I just figured the Lever t-case shifter was more of a looks thing.

The Trail line has the lever. I don't think that it's just an electronic shifter. There's a lot of vibration that comes through the lever, and you can feel it grind if you do something wrong with it.

In the case of the Runner, it's a real shifter.

I know they had/have both, even back in 94. It was just like the 4Runner - if you didn't shift it correctly you'd get a grind or not get it into gear. From a quick search that would be a NP241 t-case which is a full manual shift. There was likely an electronic actuator in the front differential, similar to the 4Runners.

Great thread everyone, thanks.

Something to remember is that even on the models with the physical lever which activates 4Hi and 4Lo, there is still some electronic actuation going on to engage the front diff, which disengages when in 2WD. So there is still some "electronic magic" going on even with the manual lever trucks.

On my 3rd gen, I really like the "all wheel drive" mode that comes with having a selectable locking center diff on the trucks with the "Multimode" transfer case as they called it. Basically, I have 2WD, 4WD Hi with center diff unlocked, so can use it on dry or wet pavement, 4WD Hi with center diff locked (which is like 4Hi on the 5th gen non-limiteds), and 4Lo (center diff is always locked in 4Lo). It makes for a very versatile system, though there are lots of buttons and levers to work to make use it properly. Probably why they changed it on the 4th gen and later models.

I loved that feature on my 3rd gen as well. As for the 5th gen when I first started searching I knew I wanted the manual shift model solely for the reason of less things to break, and the rear locker. Unfortunately the models with each come with an abundance of other components to malfunction(crawl control, multi terrain, etc) so in the end I'm going to have a lot more things to worry about farther down the road electronically. My comfort lies in the number of 5th gens sold and how many used parts will be available in the future.

The 4th gen V6 4wd models also have a multi-mode T-case.

Ah, didn't realize that. Thanks for the correction. I guess I should have assumed so given the design direction Toyota seemed to take the 4th gen (more on-road focused IMHO, due to the styling, lack of a rear locker, etc).