i have a pump for the gear oil if you need it!
H

 

Swapped the transfer case out yesterday with no major issues or surprises, and finally have my 4WD back. HUGE thanks to H-man for his expertise, help, tools, and driveway (sorry about gunking it up). I couldn't have gotten it done without him and another buddy of mine.

I did some minor surgery on the old one today. The chain was completely intact. The case had partial rotation of the front drive with 4WD engaged, although I felt no force at all while holding the front drive stationary with one hand while spinning the main shaft(s). After removing the indicator light switch, it seemed that there was a problem with the front drive shift rail. The portion of it that comes forward with 4WD engaged to actuate the switch remained in its 2WD position, resulting in no light or actual 4WD. This was in spite of the shift rail physically moving forward at the lever. I'm not sure if this is/was just a symptom or a part of the cause. Additionally, I was able to rotate the front drive rail about 20 degrees clockwise if looking at/from the front of the case. I don't remember being able to do that on the replacement case. Maybe that's a clue as to what went wrong.

Also - the other day I re-examined what I first thought were metal pieces and determined that they were just really, really hardened gunk. I was able to smush 'em up with some pliers. So, contrary to what I posted a while back, I don't think anything got shredded inside the case. I just let it go too long without changing the fluid, which again could be a clue/cause as to the failure.

At the end of it all, though, I lost all motivation to completely tear the old one apart, although I am a "how?" and "why?" kind of guy. All that matters is that my 4WD is back, and the replacement case is in much better condition than the old one. Instead of keeping the old one around for parts, I just got back from dropping it off at a local Toyota truck salvage yard for a proper burial. Thanks for the suggestions/posts here. Wish I knew exactly what the problem was, but I'm moving on....