3rd Gen SAS - Axle/T-Case Options?

[smacaulay]

Picked up a 00 Runner auto for my next build. I've been outta the game for a while so need a gut check.

Purpose: Drive family of 4 all over west coast, crawl over rocks (rubicon/fordyce, utah, colorado, etc), drive home, get slightly better fuel economy than a fj80.
Front will be 3 linked, leafs in the rear, 37's, double locked...

What axle/t-case combination would you choose and why? Options i'm considering below, but open to others (toy axle only).
1. Trail gear crawl box, in front of stock chain case to stay drivers drop. Simple, chain case is probably strong enough for my purposes. I'd go marlin, but tcases are getting harder to find in good condition, marlin never has stuff in stock, and trail gear will just send me a built unit to make it easy. Axle would then be either diamond or ruff stuff with mini outers.
2. Atlas 4-1, with fj80 front. T-case is expensive and probably overkill, but the front axle becomes much cheaper (add hellfire knuckles, longs, selectable hubs).
3. Does anyone make an adapter behind the auto to use passenger drop gear duals anymore (don't want to go the t100 chain case route)? If so, i'd probably go this route with an fj80 axle. Relatively inexpensive for enough strength.

Appreciate the feedback.

 

[Team_Jake]

Picked up a 00 Runner auto for my next build. I've been outta the game for a while so need a gut check.

Purpose: Drive family of 4 all over west coast, crawl over rocks (rubicon/fordyce, utah, colorado, etc), drive home, get slightly better fuel economy than a fj80.
Front will be 3 linked, leafs in the rear, 37's, double locked...

What axle/t-case combination would you choose and why? Options i'm considering below, but open to others (toy axle only).
1. Trail gear crawl box, in front of stock chain case to stay drivers drop. Simple, chain case is probably strong enough for my purposes. I'd go marlin, but tcases are getting harder to find in good condition, marlin never has stuff in stock, and trail gear will just send me a built unit to make it easy. Axle would then be either diamond or ruff stuff with mini outers.
2. Atlas 4-1, with fj80 front. T-case is expensive and probably overkill, but the front axle becomes much cheaper (add hellfire knuckles, longs, selectable hubs).
3. Does anyone make an adapter behind the auto to use passenger drop gear duals anymore (don't want to go the t100 chain case route)? If so, i'd probably go this route with an fj80 axle. Relatively inexpensive for enough strength.

Appreciate the feedback.

If you are dead set on Toyota axles, what you've said is what you've got. If you do go FJ80 outers on the axle, Front Range Off Road just released their keyed steering knuckles, a little less expensive than Hellfire Knucks. Slee also makes a cheaper high steer option. Advanced Adapters, Trail Gear, and Marlin all make adapters behind the tranny to use a gear-case crawl box. You can even buy complete dual cases (gear driven, passenger side drop) from TG that bolts right in.

 

[Team_Jake]

If you are interested, I have a new TG adapter plate I can sell at a discount (this one here, TACOMA T-CASE ADAPTER PLATE KIT) that I probably won't end up using (I'm probably going to end up getting an Atlas or Blackbox when I do my SAS).

 

[jkeith.w]

I If you do go FJ80 outers on the axle, Front Range Off Road just released their keyed steering knuckles, a little less expensive than Hellfire Knucks.

Really?! I'm on a waitlist for Hellfires, but would certainly look into the FROR stuff..

 

[Team_Jake]

Really?! I'm on a waitlist for Hellfires, but would certainly look into the FROR stuff..

Yep, a few days ago they posted this on Instagram:

 

[jkeith.w]

Yep, a few days ago they posted this on Instagram:

I dig it. - I'm a little concerned about how wide the key is (or how little material is on the sides, without a meaningful fillet in there) - looks like a good place to start a crack to me?:

might be totally fine with the bolts in place; I dunno.

 

[smacaulay]

If you are dead set on Toyota axles, what you've said is what you've got. If you do go FJ80 outers on the axle, Front Range Off Road just released their keyed steering knuckles, a little less expensive than Hellfire Knucks. Slee also makes a cheaper high steer option. Advanced Adapters, Trail Gear, and Marlin all make adapters behind the tranny to use a gear-case crawl box. You can even buy complete dual cases (gear driven, passenger side drop) from TG that bolts right in.

Didn't know about the FROR option, thanks for the intel! I'm aware of the Slee option, but want sometime a bit stronger. I've had the hellfires on my old 4runner (also linked 80 front) and they were easy to set up and issue free.

Buying the dual ultimates from trail gear is pretty appealing, but 2.28x4.7 with an auto seems way too low...maybe just a single 4.7?

 

[T4topher]

Didn't know about the FROR option, thanks for the intel! I'm aware of the Slee option, but want sometime a bit stronger. I've had the hellfires on my old 4runner (also linked 80 front) and they were easy to set up and issue free.

Buying the dual ultimates from trail gear is pretty appealing, but 2.28x4.7 with an auto seems way too low...maybe just a single 4.7?

Well you could always do 2.28x2.28 duals. That’s what I’m doing except I’m keeping my multimode case and doing 2.56x2.28.

 

[smacaulay]

If you are interested, I have a new TG adapter plate I can sell at a discount (this one here, TACOMA T-CASE ADAPTER PLATE KIT) that I probably won't end up using (I'm probably going to end up getting an Atlas or Blackbox when I do my SAS).

I may be interested, will definitely keep you in mind. I really need to commit to an axle...most likely going FJ80 passenger drop mainly for cost. No custom housing needed, i'd need to source a mini truck axle for a mini outer solution anyways and those are getting hard to find in decent shape. With FJ80 i'll be passenger drop, gear driven case, and will need this adapter.

 

[smacaulay]

Well you could always do 2.28x2.28 duals. That’s what I’m doing except I’m keeping my multimode case and doing 2.56x2.28.

For a fully built trail gear option, looks like 2.28x4.7 is the only option on the website. I've built crawl boxes before, but finding 2 gear driven cores in good shape is becoming a challenge.

This would likely be the route i went if staying driver drop (add crawl box in front of factory chain case).

 

[T4topher]

For a fully built trail gear option, looks like 2.28x4.7 is the only option on the website. I've built crawl boxes before, but finding 2 gear driven cores in good shape is becoming a challenge.

This would likely be the route i went if staying driver drop (add crawl box in front of factory chain case).

Ah, that makes sense. Just thought I would throw it out there. When I was looking for my crawlbox it was a pain finding one. I realized you can’t look at Craigslist or Facebook market place, only places that had them were Toyota specific salvage yards. Even looked at pick n pull, 99% of them were 2wd. Marlin crawler told me to use some guy in Colorado, he wanted 500$ for one shipped to me lol. I went to a local Toyota salvage yard (Nor Cali) and picked up a 79-83 case for 150-200$, he said they usually get one about once per week.

 

[smacaulay]

Ah, that makes sense. Just thought I would throw it out there. When I was looking for my crawlbox it was a pain finding one. I realized you can’t look at Craigslist or Facebook market place, only places that had them were Toyota specific salvage yards. Even looked at pick n pull, 99% of them were 2wd. Marlin crawler told me to use some guy in Colorado, he wanted 500$ for one shipped to me lol. I went to a local Toyota salvage yard (Nor Cali) and picked up a 79-83 case for 150-200$, he said they usually get one about once per week.

Damn, $500 each is crazy. Thinking 2.28x4.7 built unit from TG makes the most sense at this point. May be getting an FJ80 front this weekend.

 

[busmup808]

I’m in the same boat. I called all my toyota friends in WA and none of them had an extra case to spare. Called around all the Toyota yards and they wanted $500 for the case. I’m about to call back home in HI to get a case and ship it up here in WA.


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[Team_Jake]

Car-part.com is your best bet for a gear drive transfer case, ~$250 in my area. The best gear drive T-case option is the top shift case found in early 22RE engines, look up 1988 Toyota Truck, 4 Cyl, MT.

 

[T4topher]

Car-part.com is your best bet for a gear drive transfer case, ~$250 in my area. The best gear drive T-case option is the top shift case found in early 22RE engines, look up 1988 Toyota Truck, 4 Cyl, MT.

Top shift case years:
79-83 (all) 85-88 (4cyl EFI only)

Transfer Case Bible | Marlin Crawler, Inc.

 

[Team_Jake]

I'm a little concerned about how wide the key is (or how little material is on the sides, without a meaningful fillet in there) - looks like a good place to start a crack to me?:

might be totally fine with the bolts in place; I dunno.

I see what you mean, but their keyed steering for mini knuckles are exactly the same and I haven't heard of anyone having issues. FROR makes solid products, I'm sure if they did have issues on their mini knuckles they wouldn't transfer that design to the fj80 outers.

 

[Team_Jake]

Top shift case years:
79-83 (all) 85-88 (4cyl EFI only)

Transfer Case Bible | Marlin Crawler, Inc.

Yes, top shift cases were made from 79-83, but according to Marlin, they have "noisy style gears" (I don't know how noisy they are, I've never compared the two). The later top shift cases also had larger hardware and a bearing retainer clip, so I think that would make it more desirable vs the earlier style top shift cases.

 

[jkeith.w]

I see what you mean, but their keyed steering for mini knuckles are exactly the same and I haven't heard of anyone having issues.

that's good data, thanks.

 

[jkeith.w]

I see what you mean, but their keyed steering for mini knuckles are exactly the same and I haven't heard of anyone having issues.

that's good to know, thanks.

 

[clearock]

Had nothing but issues with my TG dual case (started day 1), bought it all new through them and had more down time then drive in the 1.5 yrs I had it. Sold off the new case they sent my to replace the one that I had, went with Atlas...

When shopping for axle housings I contacted FROR and took them a few wks to reply to a question and when I replied and wanted to order I never heard back from them, after read a number of reviews about FROR taken months, months, and months longer then quoted and when there was an issue FROR taken even longer to fix said (no personal exp just what I read but them not even returning my email...), I went with RuffStuff Specialties. I found they offered what I wanted and went that route, had a couple of issues with the housings I ordered, RuffStuff stood behind there product and took care of said very fast, super happy i went with RuffStuff (the housings r top notch).

FYI I have the section of tcase from the chain case laying around with no plans to use.