V8 transfer cases and year compatibility

[southern_runner]

Does anyone know which years transfer cases are compatible with the 2003 4Runner V8?

I have a replacement transfer case, from a V8, for my 2003. The two pins that are used for alignment on either side of the t-case line up properly, but seem to be a different type and size than what was on my 2003 and they are hitting and not allowing the t-case and the trans to mate up.

I'm not sure exactly what year the replacement t-case I have is; I got it from a salvage company (Lewisville Motor Co) and they told me this case was compatible.

It's almost like the replacement t-case has a rod or post of some sort when it should have a hole. So when I try to mate the t-case to the trans, the rod that sticks out of the t-case hits the hollow rod that sticks out of the transmission and prevents them from mating up.

 

[AuSeeker]

Does anyone know which years transfer cases are compatible with the 2003 4Runner V8?

I have a replacement transfer case, from a V8, for my 2003. The two pins that are used for alignment on either side of the t-case line up properly, but seem to be a different type and size than what was on my 2003 and they are hitting and not allowing the t-case and the trans to mate up.

I'm not sure exactly what year the replacement t-case I have is; I got it from a salvage company (Lewisville Motor Co) and they told me this case was compatible.

It's almost like the replacement t-case has a rod or post of some sort when it should have a hole. So when I try to mate the t-case to the trans, the rod that sticks out of the t-case hits the hollow rod that sticks out of the transmission and prevents them from mating up.

I can't tell you with certainty which year/s transfer case is a "direct" swap for a 2003 V8 transfer case....but my best guess is a 2003 only, and my reasoning why is that the 2003 5 speed transmission is a little bit different than 2004 and onward 5 speed transmissions, the 2003 is a non-sealed transmission with a dipstick and 2004 and onward 5 speeds are sealed transmissions without a dipstick and they use different ATF.

With that being said it's possible that a later year transfer case "could" work but you would have to modify the "hollow rods" and or the "rod/post" on either the case or the transmission to allow the case to mate up properly.

Both the "hollow rods" and the "rods/posts" are both alignment pins and both are pressed into the holes, apparently for the sealed transmission transfer cases the alignment pins are pressed into the transfer case and in the earlier version they're pressed in the transmission.

What I would do is check with a digital caliper to see if both type of alignment pins are exactly the same size and if so I would remove the "hollow pins" from your transmission because they would be easier to remove or drill out than the solid pins would be and then drill out the hole slightly bigger so the solid pins can easily slide in the alignment hole, if this seems like it will work then the case should work if all other measurements, bolt holes and shafts, etc. will connect properly.

 

[southern_runner]

That makes perfect sense. I'm a bit annoyed that they sold it to me as a replacement with no mention that it would not just mate up. I have tried to remove the rod, so drilling out the hollow rod does seem to be the better solution. I understand the alignment rods but they aren't really necessary as the eight bolts will hold the t-case where it needs to be.

I will likely try that route, thank you for the response!

 

[southern_runner]

Auseeker, I put a 11/32" drill bit to the first hollow pin on the transmission, and it pulled it right out...didn't even have to drill out the metal. The second one I can't quite get to (my transfer case is on a platform ready to mate, and I can only move it so much without taking it all down). I think I can get to the second one with a right angle bit.

Just wanted to let you know I think that's going to work, just remove the hollow pins and the remaining hole should be large enough to allow the index rods that are on the t-case to go in. Thanks so much for the help, I was thinking I was stuck with a transfer case I couldn't use!

 

[AuSeeker]

Auseeker, I put a 11/32" drill bit to the first hollow pin on the transmission, and it pulled it right out...didn't even have to drill out the metal. The second one I can't quite get to (my transfer case is on a platform ready to mate, and I can only move it so much without taking it all down). I think I can get to the second one with a right angle bit.

Just wanted to let you know I think that's going to work, just remove the hollow pins and the remaining hole should be large enough to allow the index rods that are on the t-case to go in. Thanks so much for the help, I was thinking I was stuck with a transfer case I couldn't use!

If the hole isn't a bit loose on the alignment pins you may run into an issue getting things to go together completely and then it also maybe very hard to get it back apart if you need too.

Good luck, hope it goes well!!

 

[southern_runner]

If the hole isn't a bit loose on the alignment pins you may run into an issue getting things to go together completely and then it also maybe very hard to get it back apart if you need too.

Good luck, hope it goes well!!

Got both hollow pins out, drilled the holes they were in out just a little bit larger for good measure and the t-case went right up to the transmission.

Only issue I had was when I was putting the eight bolts back in, the bottom right one just got really hard to turn about halfway in, and with less than 1/4" to go I snapped the head off. I think I'll be good with 7 bolts in, I may try to drill it out and re-tap it when I feel like having a sucky weekend under the truck but for now I'm leaving it.

Appreciate the suggestion, you saved me!

 

[AuSeeker]

Got both hollow pins out, drilled the holes they were in out just a little bit larger for good measure and the t-case went right up to the transmission.

Only issue I had was when I was putting the eight bolts back in, the bottom right one just got really hard to turn about halfway in, and with less than 1/4" to go I snapped the head off. I think I'll be good with 7 bolts in, I may try to drill it out and re-tap it when I feel like having a sucky weekend under the truck but for now I'm leaving it.

Appreciate the suggestion, you saved me!

I'm glad my speculation on how to solve your issue has helped, hopefully there's no more bumps in the road to get it all finished and working, update us on how it all goes!!

 

[southern_runner]

I'm glad my speculation on how to solve your issue has helped, hopefully there's no more bumps in the road to get it all finished and working, update us on how it all goes!!

Transfer case is in and seems to be working perfectly. To be fair I haven't tried 4Lo, but no dash lights and 4Hi is working great.

I do have an issue with the new front driveshaft, I got it mated to the front diff just fine but at the transfer case I can't quite get it to sit flat. One side of the driveshaft flange sits flat against the output of the transfer case, but the other side has a slight gap and I can't get it to close, even when tightening all four bolts up.

Guess I need to pull it off and see if there's any debris on the mating surfaces.