2003 4runner V8 transfer case removal

[djt294]

Hi,
I have searched the forum and found some threads on removing of the transfer case on the 2003 V8 4WD without removing the transmission (my TC actuator needs to be replaced). Specifically, I followed this thread :
Fixing the transfer case shift motor leak from within.. - Toyota 4Runner Forum - Largest 4Runner Forum

I tried to get at the 12mm bolt on the very top of the transmission case on the passenger side but I had no luck, I used extensions, wobble sockets and tried to get in with a wrench but I had no luck. I could not even land the socket on the bolt. It is a very tight area with little swing room. After trying for 2 hours I gave up, very frustrated. I looked at the manual and I can now understand why the manual says to remove the transfer case with the transmission, but I am working by myself and think it may be too big of a job to remove the transmission and transfer case as a unit. Does anyone have any ideas/tricks on how to best get at the bolts on the top of the transmission case?

thanks

 

[Tomm-]

I used a vareity of extensions and universal (wobble) joints and it broke free. With those extensions you should be able to clear the tcase completely. You can see the bolt on the top of the Tcase from rear and passenger side angle. It helps if you reach your arm up there are feel around for the bolt while using your other hand to guide your socket and ratchet in there.

My bolts were pretty gummed up - you might break the bolt head off but what are your options? I broke one. It's easier to drill out a seized bolt with the tcase out anyway. After it all, I ran a tap in the bolt holes and die down the bolts to make sure they wouldn't seize again.

Bottom line, get your socket on there and send it. You might need to move to a bigger ratchet, breaker bar, or even add a pipe on the end of your ratchet (jack handle works). Also if this is your last bolt, make sure your jack (or whatever you're using to support the tcase) is hold some of the weight of the tcase - this will take pressure off that bolt as well.

 

[djt294]

Ok, appreciate the advice, I will get longer extensions to clear the Tcase and maybe one of those flexible socket adapters ( I googled "removing hard to reach bolts").

 

[Tomm-]

Ok, appreciate the advice, I will get longer extensions to clear the Tcase and maybe one of those flexible socket adapters ( I googled "removing hard to reach bolts").

I can't recall exactly, but I think I used a 12" and 6" combined to reach it. The wobble/universal joint makes everything harder on hard to reach bolts.