write up: ADD 2wd LOW

I have a '99 manual so I know the ADD circuit pretty well. You could wire a manual over-ride to the ADD VSV's that would keep the ADD from engaging when activated. Use a DPDT and have one side open the circuit to the engage VSV and the other side supply 12V+ to the disengage VSV. Simple, and done right on the firewall. You would need to take four wires back into the cab to the switch--three if you source the 12V+ inside the cab.

Or use a relay on the firewall to do the same thing and then just one wire into the cab and an SPST switch.
 
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Yep. There are a bunch of threads on T4R about the step by step conversion.
Manual hub'd Taco's didn't usually have ABS so you have to move parts to the new spindles to keep the ABS.


This is what I did..Pretty easy. Just need about a 40 ton press for the bearings..
 
I just wired a toggle switch into the connector behind the glove box. Basically just tricks the transfer case into not engaging the front drive shaft, yet still gives 2lo. I could yank my glove box and take a picture of what and where I spliced the switch in if anybody's interested. Way easier than relays etc. 99 5spd manual tcase.
 
I just wired a toggle switch into the connector behind the glove box. Basically just tricks the transfer case into not engaging the front drive shaft, yet still gives 2lo. I could yank my glove box and take a picture of what and where I spliced the switch in if anybody's interested. Way easier than relays etc. 99 5spd manual tcase.

DO it.
 
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Ok so here's what I did. I'll just say that this is what worked for me on my 99 sr5 v6 5spd manual tcase.

I removed the glove box (2 phillips screws underneath) and the top plastic cover above the now empty glove box area (3 10mm bolts). Cut the white wire with black tracer (4wd transfer detection signal wire) and run the switch in series with that wire. Leave some slack on either side of the wire to be able to strip the wire for connections as well as put it back together if desired in the future. I just used wire I had lying around because its just a signal, and not load carrying. Check the pictures as to what I did. (note that the only reason there are two crimp connectors on each wire is because I had to lengthen the wires. I used to have the switch hidden in the glove box but that got annoying so I mounted it in the hole where my alarm light was.) When the truck is in 4lo the 4wd cluster light will be on, and when it is in 2lo it will turn off. Essentially all you are doing is tricking the tcase 4wd signal. Hope it helps!
 

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