Issue installing new used tcase in 96 4runner

[tip]

Hey guys,

I picked up a used tcase out of a 98 4Runner. My original tcase developed a bearing groan from the front output bearing and I figured it would be cheaper to replace the whole case with another used unit.

Anyway, I went to install the new used tcase and it won't seat against the trans case. There is about 1/4" gap. I tried to snug it up with the tcase mounting bolts and the bolts are way too tight, still about an 1/8" gap.

What am I missing? The case should be the same right? I removed the bolts and slid the tcase out and tried to really ram it home but still no luck. Note: I replaced the trans output seal and tcase I out seal. I tried putting the tcase in what I think is neutral. The tcase came out of a manual trans 4Runner, mine is AT. I had to swap out my sensors since they were different but everything else seemed the same.

I'm gonna pull the tcase again tonight when I get home. Almost seems like the dowel pins are a diff size... Or maybe the new trans output seal isn't seated all the way...

Any input would be appreciated! This is bugging me

 

[tip]

Pulled the tcase. The input shaft on the new one is about 1/2" longer than the original, and is wider. Should have caught that before I installed but I read all the tcases are the same from 96-98. What gives?

Maybe I can swap the input shafts?

 

[nwebb01]

Sorry to hear your troubles. I had to swap tcases about a year ago and know that the whole thing can kinda be a pain in the rear.

Might want to do some additional searching on here as there's tons of info available. I'll not 100% sure if the manual tcase and auto are able to be swapped, or not.

Trying your solution might work, but I'm not sure if the internal workings of the tcases are identical. Thought I read on here that they are not, but that was some time ago when I was prepping for my swap.

Best of luck on getting it fixed.

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