02 trans shift problem

[iowa runner]

Hi I am a long time yota driver but new to any type of online forum. I like this site though and figured I might as well join since I've visited so much. I have an 02' limited with over 160000 mi on it that runs like new... untill now. I've had this truck for 2 1/2 yrs. with no problems but 2 months ago i put a trailer behind her, I suspect for the 1st time in her life, and took a 2000 mi trip. no issues driving even through mountains all the way to CA. I arrived, detached the trailer, and drove fine for 2 weeks, than started her up after being parked one day for an hour and could move gear shift through all possitions but no gear would engage. engine revved with no movement as if in neutral. pushed her to the mechanic next door who could get her to drive in all gears but not rwd. drove from LA to san diego in fwd, took her to my mechanic down there who I trust and speciallizes in toys, and they found the issue had dissappeared! I drove every day for two more weeks and than pulled the trailer all the way back to Iowa with no problems, all gears working. a month gos by without issue and than yesterday I turn her on and no go. same problem as before, the only clue I have is a grinding noise moving the stick back to park which behaves like neutral as I can still roll her with a push while in park. the first place I went told me to rebuild the T-case. should I do that or just swap the whole trans out for a manual which I would rather have? does this problem make sense to anyone else? Is there a much cheaper fix besides t-case or new trani? I don't mind gettin' dirty but if I take the whole trani out I need a good reason to give my wife! any thoughts would be much appreciated.

 

[pat161]

Had the exact same issue with my 02 Sport at 100k, right down to the grinding when going into park and working fine when in 4wd powering only the front tires. Don't waste your time with the tranny, its definitely the transfer case. I found one at a junk yard w/ under 100k for $350 and have been going strong since, at 140k now. Only weird thing I see with yours is the vanishing symptoms, once mine stopped working that was it.

With your 02 if you do a bit of research you will find that a manual swap is nearly impossible. I say nearly because if you wanted to source the tranny, transfer case, computer and wiring harness, throttle body and other misc. parts you could probably make it happen, but finding a manual 4Runner would be far easier.

 

[iowa runner]

Hi Pat, thanks for the feedback and insight about the transfer case. I checked out your thread regarding what you went through with yours and it does sound identical to my problem, and now I don't think my truck is just in a bad mood! One response struck me that said it sounded like an electrical issue. When I move the stick back to park it almost sounds like the e-lockers groaning trying to engage. Maybe that's a dead end though. I found some options for T-cases in the meantime. I can get a salvage one for about 150 with no guaronties or I can get a rebuilt for about 600, and then there's the option of rebuilding the one I have which will probably cost at least as much as the salvaged case. What do you think? And how long did it take you to remove and then install the one on your truck? Are there any tips you can give me that might save me some headache?

 

[pat161]

Considering you are the only other person I have heard with this issue I'd say these transfer cases are pretty bullet proof, and therefore I'd feel pretty good about a used unit. But I would want to know how many miles, and if it was 150k or more I'd probably go the rebuild route.

The swap wasn't bad, of course I did it with a friend who happens to be a master tech and has done these before, and also has a shop, lift and every tool you can imagine. But honestly I would say if I could access a lift and tranny jack I could have swapped it myself following the FSM and taking my time. There's not much to dropping the case aside from unbolting and unplugging everything, dropping the drive shaft and pulling the shifter assembly apart so it can come down. Then the t-case just pulls away from the tranny, you won't even need any new gaskets as the t-case and tranny are sealed internally. IIRC we had to pull one of the cross memebers as well. Hope this helps and good luck with the rig.

 

[iowa runner]

update on trans case issue

It's been a little while but I got a salvage transfer case a week ago from my local yard. It's from the exact same vehicle as mine, an 02 limited, but it only had 60k mi. on it when it was pulled so I'm feeling good about that. Over the weekend I pulled my original transfer case out and I'm ready to install the other one. One annoying detail is that when I pulled the tc out I ganked the oil seal on the input of the transmission so I want to replace it. I am wondering if anybody knows where I can get one that I know will fit well and what the technical name is for that specific seal. Once I get into the install I'll try to post pics. The removal was fairly simple, just a lot of bolts.

 

[iowa runner]

The new transfer case went in last weekend without a hitch! She is running like a dream!:bluejump:

 

[pat161]

Glad you got it all sorted out.