Transfer case help - its hitting my skid???

[MountainBiker]

I should mention my complete set of fixes for the multi-mode transfer case hitting the Savage Skid:
- removed teeny little OEM skid and rubber damper from the TC
- Installed a new OEM transmission mount, this raised the TC >1/4"
- installed a 1/2" thick HDPE spacer at the back of the Savage skid, between it and the frame crossmember. Tap Plastics cut the spacer to my sketch, which matches the full contact area between the frame and skid. I even had them drill the two holes for the two bolts. Can't recall the price, but it was certainly under $15.

Before you think you have a complete solution, drive on bumpy ground in 4wd, with the window open to listen for contact. You need a driveline load on the TC to get the Engine/Trans/TC assembly to flex through it's full range of motion on the motor mounts and transmission mount. And the contact is most obvious when you excite a resonant frequency in your driveline, so a single bump may not show it up. When I had Tap Plastics make my 1/2" thick mount, I also bought a 1/4" mount, and before i installed the new trans mount, I needed to stack both spacers. I really, really don't want to damage the aluminum transfer case by banging it against the 3/16" steel skid, so I made sure that contact never happens with my rig, your results may vary. Of course, if I ever bend the skid, all bets are off!

FYI, if I didn't go off-pavement (washboard makes the contact the worst), I could probably get away without the spacer. But then why would I need these super heavy, suspension sagging skids? Not knocking the weight of the skids, as they are built to the proper strength if you intend to drag and/or rest the weight of the vehicle on them.

 

[Road Bull]

Pretty sure the multi-mode transfer case is larger than the older ones. I just removed a 99 transfer case and it looks bigger than the one on my 98, so the clearance issues make sense. There's not a single poster in here with a 96-98 complaining about clearance.

But I wish I had multi-mode next time...

This would explain a lot. The 2002 multi-mode SR5 has been my only 4runner and I haven't looked at an older TC side by side, but this would make sense.

I called Savage and we talked a good bit about it. The best he could figure, there were a few factors that could play into contact. He said that it could be the transmission mounts, but he also couldn't rule out conflicts with newer 3rd gens. He was surprised that I had an SR5 with contact and not a Limited though. But I am starting to think that the multi-mode TC has something to do with it.

I should mention my complete set of fixes for the multi-mode transfer case hitting the Savage Skid:
- removed teeny little OEM skid and rubber damper from the TC
- Installed a new OEM transmission mount, this raised the TC >1/4"
- installed a 1/2" thick HDPE spacer at the back of the Savage skid, between it and the frame crossmember. Tap Plastics cut the spacer to my sketch, which matches the full contact area between the frame and skid. I even had them drill the two holes for the two bolts. Can't recall the price, but it was certainly under $15.

Before you think you have a complete solution, drive on bumpy ground in 4wd, with the window open to listen for contact. You need a driveline load on the TC to get the Engine/Trans/TC assembly to flex through it's full range of motion on the motor mounts and transmission mount. And the contact is most obvious when you excite a resonant frequency in your driveline, so a single bump may not show it up. When I had Tap Plastics make my 1/2" thick mount, I also bought a 1/4" mount, and before i installed the new trans mount, I needed to stack both spacers. I really, really don't want to damage the aluminum transfer case by banging it against the 3/16" steel skid, so I made sure that contact never happens with my rig, your results may vary. Of course, if I ever bend the skid, all bets are off!

FYI, if I didn't go off-pavement (washboard makes the contact the worst), I could probably get away without the spacer. But then why would I need these super heavy, suspension sagging skids? Not knocking the weight of the skids, as they are built to the proper strength if you intend to drag and/or rest the weight of the vehicle on them.

Thanks [MENTION=67922]MountainBiker[/MENTION] for sharing the good info! How hard was it to swap out the transmission mounts? Have any pictures of the spacer you used? I just use about 7 large washers a side to gain clearance. I suspect that won't be enough down the road, but has helped stop the issue.

Do you have any pics of the spacer you are describing?

I removed the OEM TC skid. I didn't need to remove the rubber dampener as it wasn't that close to contact. I also added the washers (rear mounts only for now). >> http://www.toyota-4runner.org/3rd-gen-t4rs/196568-road-bulls-2002-sr-5-timeline-9.html#post2611532

As soon as the weather gets better I will take a closer look and better solution if one is needed.

Thanks for the additional info guys!

 

[fourfive]

How hard was it to swap out the transmission mounts?

Very straightforward.

Installation of trans mount:
1. Place floor jack on transfer case protector plate to support the transfer case.
2. Remove 4 bolts attaching trans mount to crossmember (13 ft/lbs).
3. Remove 2 bolts attaching exhaust hanger to crossmember (torque spec ?).
4. Remove 4 bolts attaching crossmember to frame (53 ft/lbs).
5. Remove 4 bolts attaching trans mount to transmission (48 ft/lbs).

 

[Road Bull]

Very straightforward.

Installation of trans mount:
1. Place floor jack on transfer case protector plate to support the transfer case.
2. Remove 4 bolts attaching trans mount to crossmember (13 ft/lbs).
3. Remove 2 bolts attaching exhaust hanger to crossmember (torque spec ?).
4. Remove 4 bolts attaching crossmember to frame (53 ft/lbs).
5. Remove 4 bolts attaching trans mount to transmission (48 ft/lbs).

Thanks fourfive! I might have to put this on my "to do" list.

 

[gamefreakgc]

I would if they weren't so darned expensive. Anyone know a good source for a cheap OEM mount?

 

[MountainBiker]

I would if they weren't so darned expensive. Anyone know a good source for a cheap OEM mount?

If you are talking about the transmission mount, it is only $80 from an online Toyota dealer. There are other sources, but I have no idea if they are oem quality. And as Fourfive said, it is a pretty easy install. The motor mounts are much more involved though, as I've read on the forums, haven't done it myself.

 

[gamefreakgc]

If you are talking about the transmission mount, it is only $80 from an online Toyota dealer. There are other sources, but I have no idea if they are oem quality. And as Fourfive said, it is a pretty easy install. The motor mounts are much more involved though, as I've read on the forums, haven't done it myself.

Yeah... I don't have $80 to spend on repairs right now... maybe I'll check out Rock Auto.

 

[MountainBiker]

Have any pictures of the spacer you used? I just use about 7 large washers a side to gain clearance. I suspect that won't be enough down the road, but has helped stop the issue.

Do you have any pics of the spacer you are describing?

Not really picture worthy, or necessary. This is a picture of the 1/4" thick spacer that I keep around in case I need to add more clearance. It's the same as the 1/2" spacer I have installed. Get HDPE material cut to 12" x 2" in your preferred thickness, place it on your skid to mark the two holes, drill it and mount it.

This is easier to work with than a stack of washers, and provides support across the whole mounting location. With washers, and strong hit in the middle of the skid could make it fold slightly, which would probably bend the bolts.

 

[MountainBiker]

I would if they weren't so darned expensive. Anyone know a good source for a cheap OEM mount?

Yeah... I don't have $80 to spend on repairs right now... maybe I'll check out Rock Auto.

SInce you said OEM, I pointed to a toyota dealer. If you are willing to go non-oem, I think they are around $30. The part number and description for my 2000 limited V6 is (check to see if that is the right number for your vehicle):

1237162120 "Engine, engine & trans mounting, trans mount 3.4 LITER, 1999-02, 4WD, auto trans"

When I google that number I get a bunch of cheaper non-oem options

 

[Road Bull]

Not really picture worthy, or necessary. This is a picture of the 1/4" thick spacer that I keep around in case I need to add more clearance. It's the same as the 1/2" spacer I have installed. Get HDPE material cut to 12" x 2" in your preferred thickness, place it on your skid to mark the two holes, drill it and mount it.

This is easier to work with than a stack of washers, and provides support across the whole mounting location. With washers, and strong hit in the middle of the skid could make it fold slightly, which would probably bend the bolts.

Cool. Thanks for the pic and type of material used. I might pick this up for the next time I plan to mess with them.