Transfer Case education

Footofgod

New member
Ok, so I do know what a transfer case is and what it does, but someone take me by the numbers.

I have a stock 91 that I am building and learning with. This is the first build I have ever done so bare with me. What are gears and/or ratios that I am dealing with and what are the upgrade options with 4:56 gears in the diffs? Will messing with the transfer case really even benefit me?
 
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Ok, so I do know what a transfer case is and what it does, but someone take me by the numbers.

I have a stock 91 that I am building and learning with. This is the first build I have ever done so bare with me. What are gears and/or ratios that I am dealing with and what are the upgrade options with 4:56 gears in the diffs? Will messing with the transfer case really even benefit me?

Abso-damn-lutely, it will. Only don't do it, because your build is getting ahead of mine and it's pissing me off.
 
Abso-damn-lutely, it will. Only don't do it, because your build is getting ahead of mine and it's pissing me off.

If it makes you feel better ill have a new OME suspension in about two weeks.


Details please. What can I do to upgrade/improve my transfer case.
 
If it makes you feel better ill have a new OME suspension in about two weeks.


Details please. What can I do to upgrade/improve my transfer case.

You're a manual trans, right? So I'll assume that you've got a gear-driven case, not the chain case found behind the 3.0 automatic. If yours is a chain-driven case, everything I mention below becomes either much more expensive or impossible.

Your stock low range is 2.26 or thereabouts, I think it's slightly higher for a manual but whatever. You can get extra-deep 4.70 transfer case gears for a super low range. The other mod is dual cases - the transfer case is in 2 sections, the reduction section and the transfer section. You can buy an adapter to run a second reduction section inline - that'd give you low range and super low range, and 2-low to boot. If you're really flush, install a second reduction section with 4.7 gears, giving you the option of low range, super low range, and stupid low range.
 
Go to marlincrawler.com and check out the transfer case page. There you can see all the possibilities your bank will allow.

You can go hardcore upgrades and run dual transfer cases OR just re-gear your current case which will be a lot better suited for most of us here. Eventually I will re-gear my xfer case with the 4.70:1 gears. I believe our stock cases have 2.28:1 gearing right now.
 
sweet! i think that is a possibility in the near future.... either that or a rear locker... kind of leaning towards the locker though
 
sweet! i think that is a possibility in the near future.... either that or a rear locker... kind of leaning towards the locker though

Now that I've got my locker in, I'm wishing I could have afforded to go with gears first - I've got all the traction I could ever want and I still lug steep climbs. If you've got the cash flow, get you a set of dual cases before you mess with lockers. A new adapter is $300, plus or minus, and you've got the skills to scrounge an extra case and shifters for chicken-scratch.

On the other hand, if a new in box Spartan falls into your lap for $200, jump on that like Bill Clinton on an intern. I breezed through some seriously crappy clay/mud last weekend I wouldn't have even considered before I put the lockers in.
 
You need to get a top shift case to drop in. I have a killer thread in mind that will explain everything pretty well. Ill see if I can dig it up.

Lemme make sure I'm straight on this, then - the v6 manual has a chain case, but the gear-driven case will bolt up? Is that right?
 
Lemme make sure I'm straight on this, then - the v6 manual has a chain case, but the gear-driven case will bolt up? Is that right?

None of the Toyota chain driven cases will bolt up. Need the adapter plate. And the R150f is 23 spline. So to run the 2.28 in the front case you need to swap in a 23 spline input gear (stock 4cyl is 21 spline), buuuut the 4.7s also come in 23 spline, so they bolt up a little easier, then you could always run the 2.28 case behind it.

But if you want to get a little deeper, the r150f is nearly identical to an ax15. So basically, you take the r150f internals, put them in an ax15 case with a ax15 tail shaft...and you can bolt up a dana 300 or an atalas....
 
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None of the Toyota chain driven cases will bolt up. Need the adapter plate. And the R150f is 23 spline. So to run the 2.28 in the front case you need to swap in a 21 spline input gear, buuuut the 4.7s also come in 23 spline, so they bolt up a little easier, then you could always run the 2.28 case behind it.

But if you want to get a little deeper, the r150f is nearly identical to an ax15. So basically, you take the r150f internals, put them in an ax15 case with a ax15 tail shaft...and you can bolt up a dana 300....

Oh, what a mess. FoG, remember what I said about things become more expensive or impossible? Stop building that miserable bas**** and get you a 22re. They tend to come in the trucks with removable tops. :D
 
Oh, what a mess. FoG, remember what I said about things become more expensive or impossible? Stop building that miserable bas**** and get you a 22re. They tend to come in the trucks with removable tops. :D


Don't listen to this guy, he's being a negative nancy :) Your runner is coming along nicely!

For starters I would just put in the 4.7 gear for your low range. IF you still fell that you need lower gears then you can add a crawl box or dual cases.
 
Trail-Gear and Marlin Crawler carry complete gear-drive T-cases, plus the adapters for the tranny. My recommendation would be to split up the build in stages--swap out your chain-drive unit for a 4.7 case initially, and if you feel you want more gearing down the road, you've already got a headstart on installing a dual-case. Your overall gearing won't change a bit, as KidV mentioned, the high-range stays 1:1--the 4.7 only comes into play in low-range. With only one case, your interior doesn't have to change--with duals, you'll have to rearrange the console/shifter set-up.
 
You guys rock! Even KidV I guess. Off to research the 4.7 box. T-case will fall about 4th in my line of things to do.
 
Just remember that you will have to run an adapter to bolt up a gear drive case behind your tranny. All the v-6 runners have chain drive cases. My buddy ran into the same problem with his so he decided just to run 5.29 in the diffs until he could round up the $1,000 bucks that it will eat up to get an adapter and a 4.7 kit for the gear driven case. If you do decide to go with a transfer case swap, check Marlin Crawler's site. Great products and great people to deal with. My 2 cents
 
Hope it helps

Trail-gears info helped me understand it:

Link:
http://www.trail-gear.com/assembled-t-cases



1979 -1995 TOYOTA PICKUP AND 4RUNNER APPLICATION INFORMATION
From 1979 to 1995 Toyota used at least 12 different individual transfer case in Pickups and 4Runners. In choosing a Trail-Creeper replacement transfer case it is important to understand the differences between the cases and how to choose the correct case for your application.

Gear drive vs Chain drive:

Transfer cases that use a chain to connect the front drive are called "chain drive" style transfer cases. Transfer cases that do not have a chain and use direct gear contact are called "gear drive" transfer cases. Transfer cases installed into trucks with automatic transmission, and/or V6 engines are usually chain drive style. Some later model 4Runners with a manual transmission and a w58 transmission also have a chain drive case. Determining if a transfer case is chain or gear driven within this year range is easy to do by looking at the rear cover of the case and counting the number of bolts holding the cover in place. If the cover has 7 bolts (as shown in photo) it is a gear driven case. If the rear cover has 5 bolts then it is a chain drive style case. At this time Trail-Gear does not support any of the chain drive applications.

Top shift vs Forward shift:
Gear driven transfer cases that have their shifter come up out of the top of the transfer case are known as "top shift" style transfer cases. Some transfer cases have a block off plate installed on the top hole and are shifted via shift trails and a shift lever located at the rear of the transmission. This style of transfer case is known as a "forward shift" transfer case.

The rear case of a dual transfer case assembly must always be a top shift style case, otherwise it would not be possible to shift the rear reduction housing or 2wd/4wd sections. The front reduction section of a dual transfer case can be either a top shift or forward shift style. Normally a forward shift case is used with a forward shift transmission. Toyota uses two different reach shift forks, 4.5" and 4.0". It is important to have the correct shift forks for the transmission used or the transfer case shifter will not work correctly.

21 or 23 spline:
All 1986-1987 turbo applications use 23 spline gears between the transmission and the transfer case. All other gear driven applications in this year range use 21 spline gears. The difference between these gears is that the 23 spline parts are a little larger and thus stronger than the 21 spline parts

If you are installing a dual case into a vehicle that has a 23 spline output transmission (such as a turbo or V6) it is recommended that you use a 23 spline dual case adapter and a 23 spline rear case input gear.

On applications that use a transmission with a 21 spline output you must use a 21 spline input gear on the front reduction housing of a dual case setup. On this application it is possible to use 21 or 23 spline gears between the front and rear reduction sections. If a 21 spline input gear is used on the rear reduction unit than a 21 spline coupler mused be used on the dual adapter. Likewise if a 23 spline input gear is used on the rear reduction unit than a 23 spline coupler mused be used on the dual adapter.

We strongly recommend that 23 spline components be used between the front and rear reduction units on all dual transfer case assemblies. The 23 spline hardware is stronger than the 21 spline. This is not a problem at the interface between the transmission and the transfer case with a stock or mildly built 4cyl motor. As engine power is delivered through the first transfer case into the second case the torque is multiplied by a factor of 2.28 when the transfer case is in low range. When both reduction sections of a dual transfer case are engaged there is 2.28 times as much more torque placed on the rear input gear/coupler as compared to the front input gear/coupler.
 
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