So, I've been working for the past WEEK on changing my clutch and installing dual cases. I bought a complete dual case assembly from someone with a V6 4Runner who was putting in a 351.

Basically, have everything in place now, just waiting on transfer case mounts (because I'm too big a dumbass to order them before starting installation...) to finish up.

A couple issues:
- The wiring on the transfer indicator switch is trashed. Can I just cut and splice it in with the existing wiring? (Any compatibiity issues between the 4Cyl switch and the V6?) The switch off the old tcase is much larger and won't thread in the hole of the 4 cyl case. I can live without the 4WD light, but is this also what tells the ADD to engage?

- Maybe this issue will clear itself up when I get the mounts, but it looks like the driveshaft is awful close to the rear heater hoses. Can I keep the rear heater, or will those hoses have to be removed and blocked off?

- Speedometer - I'll need the VSS right?

 

Might just lock the ADD front end in:
- http://www.4x4wire.com/toyota/tech/add/

For the rear heater hoses, this is what I did, soldering on some 90 degree brass elbows onto the heater tubes and routed those so the hose was flush to the bottom of the floor pan:



- http://www.4crawler.com/4x4/CheapTri...larCrossmember

I did also raise the center console/heater 1":
- http://www.4crawler.com/4x4/CheapTri...tml#SeatHeight

 

Aaaargh - what an unbelievable PITA day ...

First, I come home and UPS has delivered the remaining parts, so I get the tranny mounts installed and everything lines up well, I should have quit while I was ahead.

Then I get the wires extended for the speedo and 4WD switch. No major problems with that (but then I haven't tested it yet either)

So, I go to put the driveshafts in, and as anticipated, the rear DS is all in the heater hoses. So, the rear DS has to come out so I can relocate the heater stuff. 4Crawler - remember what size fittings those were?

The front driveshaft won't even go in - like the holes won't line up, and the double cardan hits the tcase. So the crossmember is going to have to come out so I can diagnose that. Are the 4 cyl flanges on the front output different than the V6 flanges and the rear?

Then, a buddy comes over to help we reweld the shifter, and I didn't put the cap on before, so that will have to be redone.

What a day

 

Forget the fitting size, I did that work about 8-9 years ago and got rid of the rear heater about 5 years ago. Maybe 1/2" or so, whateve fits over the stock tubing.

Not uncommon for drive flange holes to be different. Two choices are to mark and drill the new flange to fit the shaft or swap in the old flange.

 

What about running the front DS with the double cardan at the diff instead of the tcase?

(Won't necessarily solve the flange pattern issue, but will help a clearance issue between the case and the double cardan housing)

 

Took it for a RWD test drive last night - seems everything is working!

What's the best way to seal up the extra shifter hole? (I have a twinstick there BTW)

 

You can get a shifter boot for a twinstick shifter if that is what you are looking for.