(Another) FJ T-case swap question

[xtremewlr]

is it easier to do the FJ swap into a 2WD 4runner? I love my 4runner but it's RWD and it's obviously a bit limited for capability and I've thought of perhaps tackling this project with the help of friends.

Probably not easier since there would be a lot more work involved.

You'd need to swap the transmission as well since I'm fairly sure the 2wd trans can't be changed to work with a tcase. It's not a simple tail housing swap.

You also need to install a front differential and associated parts for the front axle driveline stuff.

The FJ tcase does make it easier in that you don't have to deal with any electronics at least.

I'm gathering parts to do a 4wd conversion on my daughter's 2013 Tacoma prerunner so have done some research on this.

 

[aquilon]

guess I'll sell it then

 

[4RunnerAquasport]

Not ready to do the swap, but went ahead and picked one up while prices are reasonable. [MENTION=459231]xtremewlr[/MENTION] not as clean as yours because of the rust factor here in Fla, but 2012 4Runner-130k miles $205 + $50 core. Didn't have the shift knob but I can probably find one of those cheap enough.

 

[xtremewlr]

Not ready to do the swap, but went ahead and picked one up while prices are reasonable.
[MENTION=28542]Extreme[/MENTION]wlr not as clean as yours because of the rust factor here in Fla, but 2012 4Runner-130k miles $205 + $50 core. Didn't have the shift knob but I can probably find one of those cheap enough.

Very nice! Mine was a 2011FJ case with the same mileage. No core on mine but I paid the same overall price, $250.

You bring up a good note too. 5th gen 4Runner tcase with manual shift is an option for this swap. Same as the FJ case. I don't know enough about the 5th gen 4runner to know what, if any, tcase options there are.

 

[aemravan]

I am keeping an eye out , and will probably do the same and pick up a local T-case very soon.

I currently have some very good looking options for sub $200 within a 1 hour driving radius with no core charge and both between 100-120k miles.

 

[4RunnerAquasport]

Very nice! Mine was a 2011FJ case with the same mileage. No core on mine but I paid the same overall price, $250.

You bring up a good note too. 5th gen 4Runner tcase with manual shift is an option for this swap. Same as the FJ case. I don't know enough about the 5th gen 4runner to know what, if any, tcase options there are.

I think the 5th gen case would be the same in all of their manually shifted part-time options. (Early Trail, TRD Offroad, TRD Pro) My 5th gen Limited AWD is a little different than my 03' V8 in that there is no separate switch in the dash for the center diff lock. The t-case may very well be the same as my 03' Full time awd, but with the center diff switch incorporated into the console dial. The base SR5 has the dial but is part time so I'm not sure how that one is set up, and if it would work in the 4th gen.
I wonder if the 5th gen actuators are prone to the same problems, I may have to buy another manual shift for my 5th gen, just in case lol.

 

[ktom3001]

Awesome modification, I'm super jealous.

 

[mphillips_90]

The FJ tcase has an internal oil pump that is driven by the chain in 2wd and 4wd. Having the front driveshaft turning in 2wd will do nothing to the tcase, will not cause frothing of the oil or build up pressure or do anything else bad that some people might think or claim. They are full of shit. I say this from personal experience with my 4runner. I daily drive it since it's currently my only vehicle.

From one more member, thank you so much xtremewlr. I replaced my tcase with another electric one last year due to the actuator and now that actuator has frozen up too. I actually took a hammer to it and broke it apart because it got stuck halfway between 2 low and 2 high and I was dead in the water. Have had my fj case sitting around for about a week and waiting on my twin stick kit from low range but I might not even go that route now. I’ve been trying to get up with rst for the Upgraded spring kit and add wiring harness and have been stressed out from reading the thread on the Tacoma forum about his business going under as we speak.
You’ve lowered my blood pressure for sure.

 

[xtremewlr]

From one more member, thank you so much xtremewlr. I replaced my tcase with another electric one last year due to the actuator and now that actuator has frozen up too. I actually took a hammer to it and broke it apart because it got stuck halfway between 2 low and 2 high and I was dead in the water. Have had my fj case sitting around for about a week and waiting on my twin stick kit from low range but I might not even go that route now. I’ve been trying to get up with rst for the Upgraded spring kit and add wiring harness and have been stressed out from reading the thread on the Tacoma forum about his business going under as we speak.
You’ve lowered my blood pressure for sure.

Yeah, my only advice regarding RST.

AVOID AT ALL COST!!

 

[aemravan]

Yeah, my only advice regarding RST.



AVOID AT ALL COST!!

Its been literally 5 weeks since I reached out to them wanting to spend my hard earned money and literally have yet to get a response. I am VERY glad I never placed the original parts order I was under the impression I needed..

Sent from my SM-G970U using Tapatalk

 

[mphillips_90]

Its been literally 5 weeks since I reached out to them wanting to spend my hard earned money and literally have yet to get a response. I am VERY glad I never placed the original parts order I was under the impression I needed..

Sent from my SM-G970U using Tapatalk

Right, I was about to drop money on one of their twin stick t cases cause I just wanted a quick swap before I realized that its really not much effort to gather everything yourself.
The stories on tacoma world right now is pretty sad. Some peoples build have been there since like 2019.

 

[xtremewlr]

From one more member, thank you so much xtremewlr. I replaced my tcase with another electric one last year due to the actuator and now that actuator has frozen up too. I actually took a hammer to it and broke it apart because it got stuck halfway between 2 low and 2 high and I was dead in the water. Have had my fj case sitting around for about a week and waiting on my twin stick kit from low range but I might not even go that route now. I’ve been trying to get up with rst for the Upgraded spring kit and add wiring harness and have been stressed out from reading the thread on the Tacoma forum about his business going under as we speak.
You’ve lowered my blood pressure for sure.

Re: Upgrade spring kit.

So I just did some research on this and everything I'm seeing only points to the gear driven tcases from Toyota needing this upgraded spring kit. I haven't seen anything for the chain driven FJ tcase.

And I haven't felt like it's been needed with mine, at least not yet. I don't know of that same spring can be swapped into the FJ case or not or if it's actually even needed. Kinda like the twin stick. It's nice, it looks cool but I haven't felt like I really NEED to have a twin stick with the option of 2LO. I think I need a rear locker more than I need 2LO or a twin stick honestly.

And yeah, I have one sitting on the side lines too. :heh:

And side note - just over 8500 miles on my swap, with the stock, non-ADD front axle. Nothing has blown up yet. Everything works great still. Turned 300k miles on the 4Runner the other day as well.

 

[Hatfield405]

[MENTION=459231]xtremewlr[/MENTION] Thanks for all the info!! It's good someone is getting this out there.

Just picked up a new to me 4th gen this winter and have had nothing but problems with the 4x4 system (especially in cold weather). I've been looking at info on this swap off and on for some months now and like everyone one else found the info for RST. Glad I hadn't pulled the trigger on anything yet.

Can you tell me about running a manual FJ case. Can you switch from 2hi to 4hi while in gear/moving? Switching from 4hi to 4lo requires transmission to be in neutral? Why would I need a twin stick? I'm not sure of the advantages of 2lo? Like you said, a locker seems more important. Excuse the ignorance, never owned anything with a manual tcase, just electronic actuators.
Thanks again!

 

[xtremewlr]

[MENTION=459231]xtremewlr[/MENTION] Thanks for all the info!! It's good someone is getting this out there.

Just picked up a new to me 4th gen this winter and have had nothing but problems with the 4x4 system (especially in cold weather). I've been looking at info on this swap off and on for some months now and like everyone one else found the info for RST. Glad I hadn't pulled the trigger on anything yet.

Can you tell me about running a manual FJ case. Can you switch from 2hi to 4hi while in gear/moving? Switching from 4hi to 4lo requires transmission to be in neutral? Why would I need a twin stick? I'm not sure of the advantages of 2lo? Like you said, a locker seems more important. Excuse the ignorance, never owned anything with a manual tcase, just electronic actuators.
Thanks again!

RST has gone out of business because the owner is shady as all hell and screwed people out of money. So you wouldn't be able to go that route anyhow.

My swap is coming up on 14,000 miles now, without any issues. Still works great.

The transfer case works just like it would have in the FJ. You can shift from 2WD to 4HI while moving. Safe max speed is something like 25mph I think.

You are correct, to shift from 4HI to 4LO, you need to come to a full stop and put the transmission into Neutral. Then you are able to shift into 4LO.

IMO, a twin stick is not needed with an automatic. They look cool and work great. But they are better suited and more beneficial in a manual vehicle. I decided not to go twin stick and have no regrets.

 

[bob3dsf]

I think the 5th gen case would be the same in all of their manually shifted part-time options. (Early Trail, TRD Offroad, TRD Pro) My 5th gen Limited AWD is a little different than my 03' V8 in that there is no separate switch in the dash for the center diff lock. The t-case may very well be the same as my 03' Full time awd, but with the center diff switch incorporated into the console dial. The base SR5 has the dial but is part time so I'm not sure how that one is set up, and if it would work in the 4th gen.
I wonder if the 5th gen actuators are prone to the same problems, I may have to buy another manual shift for my 5th gen, just in case lol.

That's a center diff switch? I looked at a 5th gen recently and originally thought that's what it was, but it seemed to only be a lock for the dial positions. I just sat in it, no driving, and didn't have time to look closely.

 

[4RunnerAquasport]

That's a center diff switch? I looked at a 5th gen recently and originally thought that's what it was, but it seemed to only be a lock for the dial positions. I just sat in it, no driving, and didn't have time to look closely.

Yea, I probably could have made that a little more clear. Technically in the 5th gen Limited, there is no separate center diff switch like on the 4th gen dash. There is a single dial. It has you switch from 4hi unlocked (Full time AWD) to 4hi Locked or 4 Lo Locked with that dial. And yes you are correct that little button is just a lock for the dial positions.

So basically when you switch from the 4hi unlocked to 4hi Locked, it's doing the same thing as 4th gens diff switch on the dash. It's still electronic servos making the switch in the center diff. That's where I should have omitted the "incorporated" part of my statement.

The manual t-case does not have the electronic servos that go bad. But it stays in 2wd until you move the lever into 4hi, and then the front diff has a system that locks the hubs.

It can be a little confusing. There are threads in here that delve further into a better explanation. I came from the old school manual locking hubs and manual t-case shifters in my old pick ups, so I had to do a little reading myself when I first bought this 5th gen years ago. I may look into putting a manual t-case in my 5th gen Limited in the next year or so also.

 

[bob3dsf]

Yea, I probably could have made that a little more clear. Technically in the 5th gen Limited, there is no separate center diff switch like on the 4th gen dash. There is a single dial. It has you switch from 4hi unlocked (Full time AWD) to 4hi Locked or 4 Lo Locked with that dial. And yes you are correct that little button is just a lock for the dial positions.

So basically when you switch from the 4hi unlocked to 4hi Locked, it's doing the same thing as 4th gens diff switch on the dash. It's still electronic servos making the switch in the center diff. That's where I should have omitted the "incorporated" part of my statement.

The manual t-case does not have the electronic servos that go bad. But it stays in 2wd until you move the lever into 4hi, and then the front diff has a system that locks the hubs.

It can be a little confusing. There are threads in here that delve further into a better explanation. I came from the old school manual locking hubs and manual t-case shifters in my old pick ups, so I had to do a little reading myself when I first bought this 5th gen years ago. I may look into putting a manual t-case in my 5th gen Limited in the next year or so also.

Ahhh, ok. I guess I was sitting in a limited. I didn't even look. That dial was the only one I saw.

 

[aemravan]

Bringing back this glorious thread. Just ordered my T-case from a local yard that will be working on pulling it from the car between today/tomorrow. If all goes well i'll have a T-case in the garage ready for a swap by Thursday this week.

Taking a BIT of a gamble here but I am about 95% certain everything will work out. The T-case is coming out of a 2015 4runner with only 88k miles on it and they are only charging me $214 for the case and the guy is going to try and sneak the shifter into there for free, if not i'll be at $300 total which is still ridiculously low to me. I'll probably be able to offload my factory Tcase for that amount since its still perfectly fine with only 140k miles on it. I had no idea the 5th gen's had a manual shift option for a T-case.. but everywhere i have checked it is showing up as a replacement option for the FJ's, so it should work. Not sure if the shifter is the same or not, but since it has to be modified anyway I don't think it'll be an issue..

Pretty excited to get this done, hopefully by end of the month i'll be on a manual T-case.

 

[wtcnbrwndo4u]

Bumping this thread back up from the dead to add a key install detail that may help others. I had my manual t-case installed this past week and it's great! However, I don't have a body lift installed.

Instead, what we did was use two 1" spacers and longer bolts on the rear two bolts holding the transmission shifter down. The front left bolt spot was cut off, so only three total bolts holding the shifter (no problems there). But this avoids a body lift, which I do not want to do at this juncture.

Naturally, this causes the shifter to push out of the shifter trim. The simple fix with that is to remove top two layers of the shifter, add a shifter boot, and cover it up. The dash shows you what gear you're in anyways. Note in my picture I ended up cutting around the shifter trim to try to make it fit, without realizing I could've taken off the top two layers of the shifter.

 

[Tonguss]

Happy to help, man!

Believe me, I went through all the same shit you have when I first started considering the swap. Figured instead of sending people over to dig through my build thread, I'd just compile the pertinent information here and make it easier for others to find.

Sorry for resurrecting an old post but was the new drive shaft custom made? Or was it a different drive shaft from a different toyota thats'll work. thank you