Topic: Cracking the Case

[kenny]

hello, new guy here.  I recently decided to install duel transfer cases and proceded to yank the extra case I needed from a '88 4runner(top shifting).  while trying to remove the first section (the section I need) from the rest of the transfer case, i've become stuck.  it seems to slide out about 2''-3'' but then gets hung up at the top.  One of the two sliders has a flattened end so that it will not slide through the case.  I've tried pulling and twisting (though doing both gently) and seemed to have gotten nowhere.  If any one knows how to get this apart I would be much abliged if you would let me Know.  I hope I have made my problem clear.

[BigMike]

Welcome to the Forum, Kenny  

What is happening is possibly four things.

One, you need to remove the plug with the wire coming out of it (4WD Light Indicator Switch) from the top of the passengers side of the t/case.

Two, you need to remove the retaining balls (2) and spring (2) from both side from the top from the two opposed 6mm Allen head bolts.

Three, you need to get inbetween sections 2 and 1 of the t/case to get to a second fork located in the third section as per the following image:

[img align=center]http://www.marlincrawler.com/java/gearpie.jpg[/img]
[img align=center]http://www.marlincrawler.com/java/gearpieb.jpg[/img]

You don't have to split down section 4 from 3, just seperate (remove some bolts) section 2 from section 1.

Because just behind section 1 is a fork with a roll pin that you must remove since you have a 85 and newer EFI case with the tabs at the front of the rods.

Or Four, the interlock pin is locking the two rods in place. To get the rods out, you will have to shift the t/case into 4WD High Range, which would be both rods pulled all the way forward at equal lengths and the two grooves on the front fork and slider head are ligned up.

Good luck, and let us know how it goes!  

Regards,
BigMike