It is driving me nuts. I pulled the speedo cable and put it on my workbench. Connected one end to a drill and spun it. It worked.
Next I connected the cable to the cluster. Attatched drill and spun it. It worked.
Next install cluster and cable in the truck. Before connecting the cable to transfercase I spun the cable. It worked.
Attach the cable to Tcase and go for a ride. No work

So I am assured it is a problem with the Tcase. I am wondering if the Toyota gear is made of plastic. I know some early CJs had them in plastic and they would get chewed up.

Is it possible to take off the rear housing to access this gear with the Tcase still in the truck? Or is it a complete removal?
Heck I may jsut have to get a GPS for speed.

Oh well I had to vent, I had a rather good day by changaing all battery cables to 2 gauge and cleannig up the wiring, and getting the horn to work.
Time for a beer.

 

All the ones I've ever seen were plastic:

Toyota:



Ford:

 

Just beat me. I did find that first pic, and i went and pulled my gear. And it isnt chewed but it looks worn. Unless the gears are supposed to be rounded in the center? I am believving they are flat across so i need a new one. Do I need an entire assembly or can the gears themselves be found at the dealer?

 

You might be able to swap the gear, just count the teeth so you keep your speedo the same.