Dual Transfer Case Help

Does anyone live in the central Washington state area that know how to assemble a dual transfer case setup? I need some help and willing to pay.

Summary:
Trail-gear dual case kit, mini truck crawl box, & FJ tcase with twin stick mod. The crawl box is a 21 spine and need to local a 23 spine gear. I have a garage with tools minus a press or i can pack it up and head to yours.

On a related note, I'm still on the hunt for a 4x4 rear driveline for an 05-11 tacoma, 4 banger with a manualtrans. Does anyone have any leads?

 

No one?

 

I do, but sounds like you need to get a 23 spline coupler for the crawl box if I read that right.

 

Could I convert it with the following gear?

https://sidetrackedoffroad.com/sumo-gear-toyota-2-28-23-spline-transfer-case-input-gear/

 

No, don't use trail gear for parts. Get a marlin crawler 23 spline input.

 

What's been your experience with trail gear?

 

Also, I'm not 100% sure about the fj t case but its very similar to the 1st gen case and you have to take it all apart to modify the shift forks to be able to use the twin sticks. I used front range. If you look at my link you can see what is needed. If you are not a mechanic just stick to single for now until the front setup is done.

The front case is not that hard but you will need a hydraulic press.

 

Look at my build thread. Its not just my experience. Its common issues. All that aside, marlin gears are made way better. Same price basically as well

 

I did the fj twin stick mod and it was really easy. It functions great but now I want to add the second case

 

Did you have to take the case apart and cut the fork down? If you did that the crawl box is nothing for you. You just need a $100 press from harbor freight

Do you have the old toyota gear drive case already?

 

Yes but it wasn't bad. I had good instructions to follow from front range.

The $100 press from harbor freight, did you have to have any additional special adapter?

 

You are gonna have to get the trail gear dual case adaptor for the 2nd gen. Its gonna be a tranny plate, the 90's toyota reduction gear that you get off the complete t case and then the main adaptor that gets you to the fj case.

https://trail-gear.com/drivetrain/t...2005-2015-tacoma-dual-case-adapter-kit-1.html

You just need to order the 23 spline input from marlin and get the bearings too. The input and output I believe. ITs the only big bearings they have. Get the little one too. 3 bearings from them and the input shaft.

 

I got the trail gear dual case kit but that's it. Sounds like i need to order the 23 spline and three bearings.

 

Yeah, marlin is out of stock on the basic ones but i just got the competition one. You can get trail gear and you will be fine but its not as good. The bearings are just because unless you have a bearing removal tool you cant get them off and it is like $250 on Amazon. Its a knock off yukon press kit. If you don't need that just get the hydraulic press and new bearings. make sure you don't use the little gear off the old input either. I have a bunch of pics on my thread. I made all those mistakes but if you cant pull the bearing you will be fucked.

 

Thank you for the advise. Really appreciate it.

 

Got it figured out...just waiting one more part (23spline replacement gear)

 

looks good. Idk shit about manual trans. Why does it look like there is an adaptor in front of trans shifter?

 

Just a normal factory piece