Exploded transfer case

[Highlex]

Went wheeling, only on 33s but I guess I wrecked my transfer case. More specifically my center diff lock.

When I'm in 4wd with center diff unlocked, I can rip around and there is no bad noises, AWD works perfect, then when I locked center diff and try to go offroad, tons of bad noises, loud banging and popping, sounds like the center diff is only half locked or something. Makes this noise only when center diff is locked, noise is louder when I am turning also. bang-bang-bang-

A couple questions. Anyone here about this kind of breakage before?

Can t-case be removed separate of tranny?
Are all t-cases the same? Mines a 2004 V6 sport, do I need to get a case from a 04-05 runner or will newer work as long as its V6?

Thanks!

 

[swapmeet]

Never heard of it, but that sucks. Hope someone can help.

 

[762x51]

Since you have the v6 you dont have the full time 4x4 that the v8's have. That is why it only makes noise when trying to engauge 4x4. Yes the xfer case can be split from the tranny, and that is what you will have to do in order to find the problem. I just dropped mine to fix the actuator leak and its not too bad of a job. Hope you can get her all fixed up.

 

[JB.]

First I've heard of that in 10 years.

In the meantime, probably best to leave it in AWD. If you think you might leave it alone for a while, maybe do a drain and fill.

 

[BlackWorksInc]

First I have heard of it, but wouldn't surprise me that the CDL portion of the actuator has bound up/failed in some way and is not correctly engaging. I should have taken a picture of the last one I had apart, but they get some nasty gunk build-up on the gear/splines that glues them to the gears when they aren't used regularly.

Transfer case can be dropped separate from the transmission and is not too bad to take apart.

 

[GLP]

Dropping the TC and splitting it is not that bad. Here is a write up on how to do it to fix the actuator leak. The FSM details how to do a complete teardown and rebuild.

http://www.toyota-4runner.org/4th-gen-t4rs/182074-fixing-transfer-case-shift-motor-leak-within.html

 

[Highlex]

Thanks for the advice, maybe i'll switch to synthetic gear oil before I give up on it, however I don't see that helping at all.

The woman I bought it from was the original owner and never used center diff lock in over 10 years, so it likely failed from not being used enough.

I might end up swapping in a used tcase.

Are all the V6 tcases the same, or am I best looking for one from 03-04 sport? Did they change year to year, or in 05+?

 

[BlackWorksInc]

Thanks for the advice, maybe i'll switch to synthetic gear oil before I give up on it, however I don't see that helping at all.

The woman I bought it from was the original owner and never used center diff lock in over 10 years, so it likely failed from not being used enough.

I might end up swapping in a used tcase.

Are all the V6 tcases the same, or am I best looking for one from 03-04 sport? Did they change year to year, or in 05+?

The issue might be that it isn't engaging properly, unless you split the case to asses the damage you won't know for sure. It might be as simple as cleaning up the inside of the transfer case, then disassembling the actuator partially and cleaning it up inside to restore functionality.