Transfer case . transfer cases in first and 2nd gen trucks

Overhaul manuals available at the bottom of this post .
If you can find a manual , send me a pm .
A FREE SERVICE MANUAL FOR YOUR TRUCK https://charm.li/Toyota/2010/

This post is dedicated to the VF2BM transfer case and all its components .
This post will show you how to diagnose and properly repair the transfer case in your truck
I am always in edit mode ....this post will always be updated weekly .
Check back as often as you like .






Are you effected by the TSB ? Date:2011-07-13 Automatic Disconnecting Differential (A.D.D.) Shift Actuator Inoperative

Type in your VIN # and see what,s been done to your truck at the dealership
http://www.toyota.com/owners/web/pages/home

Type in your VIN # here and see if there are any safety concerns or recall,s on your truck
http://www.toyota.com/recall

Here is an overhaul manual
https://www.atsg.us/atsg/transfer-case-1/toyota-a340-transfer-case.html

Here is the complete parts manual for your truck showing diagrams and prices as of Oct/2014
2013 Toyota Tacoma Pickup.pdf



HERE IS WHAT YOUR MANUAL SAYS
Shifting between H2 and H4
-Shifting from H2 to H4
Reduce the vehicle speed to less than 62 mph (100 km/h) and turn the
front-wheel drive control switch fully clockwise.
-Shifting from H4 to H2
Turn the front-wheel drive control switch fully counterclockwise.
This can be done at any speed. You need not depress the clutch pedal.
(manual transmission)
If the four-wheel drive indicator light or the 4LO indicator light blinks
-Shifting from H2 to H4
• If the four-wheel drive indicator continues to blink, drive straight ahead
while accelerating or decelerating.
• If the four-wheel drive indicator continues to blink and the buzzer
sounds, stop the vehicle or reduce the vehicle speed to less than 62
mph (100 km/h). Operate the switch again.
-Shifting from H4 to H2
If the four-wheel drive indicator continues to blink, drive straight ahead
while accelerating or decelerating, or drive forward or backward in a short
distance.
A Tundra transfer case , but awesome explanation of how our transfer cases function
https://www.youtube.com/watch?v=4UoBCIjWIoU

Toyota VF2AM/VF2BM
Manufacturer: Aisin Seiki
Number of speeds: Two
High: 1:1
Low: 2.57:1
Case (or housing) material: Aluminum
Front output drive type: Chain (driver side drop)
Availability or aftermarket parts and support: Medium - Dual case kits, adapters
Input spline count: 23 or 26
Rear yoke: Fixed flange
Planetary gear: Yes
Output shaft spline count: 27
Shifter type: Mechanical or electrical


HOW TO CHANGE YOUR FLUID WITH PICS ( WRITE UP )http://www.tacomaworld.com/forum/2n...ront-diff-transfer-case-oil-change-howto.html

Need lower gearing ?

https://www.marlincrawler.com/trans...oma-2nd-gen/dual-case-tacobox-40-liter-1gr-fe

Here is the complete repair manual for your truck http://www.customtacos.com/tech.old/files/05FSM/repair.html


and the complete repair manual for your older truck . Download them while they are there

IN depth diagnostics when 4x4 doesnt engage
https://www.tacomaworld.com/threads/4wd-wont-engage.747823/
What it looks like inside the transfer case

https://www.tacomaworld.com/threads/inside-the-05-tacoma-t-case.131275/

Guy has no power to the front actuator and no power to the locker in the rear diff 2006 second gen
https://www.tacomaworld.com/threads...-case-or-diff-actuators.695818/#post-24610139

https://www.youtube.com/watch?v=ZJESG91GbCQ&feature=emb_title

For you guys with the w59 transmission , look here http://web.archive.org/web/201011270...searchable.pdf

Write up with pictures diagnosing front add
http://www.4x4wire.com/toyota/tech/add/

Stuck in 4hi
https://www.tacomaworld.com/threads/stuck-in-h4.731962/


VF2BM Transfer
Transfer System: Precaution, Problem Symptoms Table
Transfer Oil: Adjustment
Transfer Case Oil Seal: Removal, Installation
Extension Housing Oil Seal: Removal, Installation
Transfer Assembly: Components
Transfer Assembly: Removal, Disassembly, Inspection, Reassembly, Installation
Touch Select 2-4 And High-low System: Parts Location, System Diagram
Touch Select 2-4 And High-low System: Inspection

Most common problems .

4x4 Issues, Front diff actuator or t-case actuator?http://www.tacomaworld.com/forum/2n...sues-front-diff-actuator-t-case-actuator.html





Does the transfer case only go into 4x4 with the truck off ?
http://www.tacomaworld.com/forum/2nd-gen-tacomas/270102-4x4-only-engages-when-truck-turned-off.html

How to troubleshoot the actuator on the front diff Write up ( with pics )
http://www.tacomaworld.com/forum/2nd-gen-tacomas/263525-how-trouble-shoot-4x4-actuator.html

How to troubleshoot the transfer case motor thats mounted to the side of the transfer case https://www.tacomaworld.com/threads/transfer-actuator.353584/page-2

2HI and 4 Hi work but it wont go into 4 low
https://www.tacomaworld.com/threads/another-4x4-probem-system-wont-shift-into-4lo.257247/


Shift knobs / shift boots / ebrake boots
https://www.infocushift.com/shiftknobs/
More great information for diagnostics http://www.itpstrategic.com/samples/UOT/QT312H 4WD COMPILATION FINAL.pdf

Front hub/ actuator repair ...do it yourself http://www.tacomaworld.com/forum/2nd-gen-tacomas/285250-2005-front-hub-actuator-repair-diy.html

Stuck in 4 low ? http://www.tacomaworld.com/forum/2nd-gen-tacomas/299498-2005-stuck-four-low.html

Flashing 4x4 light http://www.tacomaworld.com/forum/2n...d-flashing-not-engaging-where-do-i-begin.html

Is your transfer case noisy http://www.tacomaworld.com/forum/2n...r-case-chain-can-anyone-else-hear-theirs.html

Why does the truck bounce when turning tight corners
http://www.tacomaworld.com/forum/2nd-gen-tacomas/250338-switching-2wd-4wd-constantly.html


Noisy Transfer case with J shift pattern ( early model }
https://www.tacomaworld.com/threads/j-shift-t-case-rebuild.406753/page-2

SPEEDOMETER ISSUES ?
Hypertech speedometer calibrator http://www.hypertech-inc.com/products-speedometer-calibrator.aspx

https://www.rocksolidtoys.com/single-post/2017/08/29/T-Case-Worm-Gear-Install

https://www.tacomaworld.com/threads/transmission-swap-write-up-s.384303/


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MODS !!!!

Skid plate reviews
http://www.tacomaworld.com/forum/2nd-gen-tacomas/307109-aftermarket-skid-plate-reviews.html

RCI skid plates is now a Vendor https://www.tacomaworld.com/threads/rci-is-now-a-vendor-on-tw.413234/

Dual transfer case set up http://www.lowrangeoffroad.com/yotamain/inchwormgear.html

Twin transfer case set up . These guys have you covered
http://www.lowrangeoffroad.com/yotamain/inchwormgear.html

INPUT SHAFT SWAP
https://www.tacomaworld.com/threads...s-for-fj-case-for-manual-transmission.714337/

Crawlbox
https://www.tacomaworld.com/threads/official-crawlbox-bs-thread.422186/

Removing the ADD system . A fantastic write up showing everything you need to remove all the computer controls to go full manual .
https://www.tacomaworld.com/threads/how-to-deleting-add-system.427258/

3rd gen diagnostics
https://www.tacomaworld.com/threads/4wd-actuator-troubleshooting-transfer-case-and-add.578262/

The best information possible for all your first generation transfer case needs
Write up with pictures done by
turbodb
https://www.tacomaworld.com/threads...on-for-replacement-swap.753707/#post-26858426




INSTALL A V8 ENGINE
http://www.marks4wd.com/engine-conversions/bell-housing-adaptors/ls-v8-engines/mfk650g3.html


Swapping in a manual transmission from automatic and here . Is it really worth the trouble and money ?

https://www.tacomaworld.com/threads/safetydang-dc-build-4wd-swap-manual-trans-swap-thread.247243/

Swapping in an A340F to a W59 Jshift transfer case J shift transfer case installs with pics https://www.tacomaworld.com/threads/lets-see-your-fj-case-swap.455278/

FJ swap https://www.tacomaworld.com/threads/lets-see-your-fj-case-swap.455278/

BUILDING OFFROAD TRANSFER CASE OR FOR TURBO AND SUPERCHARGED ?
http://www.fourwheeler.com/how-to/t...29-0207-toyota-transfer-case-rebuild-upgrade/

http://www.f150hub.com/drivetrain/toyota-rf-vf.html

https://www.marlincrawler.com/tech/transmission/transmission-gear-ratio-chart




http://www.tacomaworld.com/forum/fj...ewly-re-designed-transfercase-skid-plate.html

Superduty transmission mount http://www.tacomaworld.com/forum/4x-innovations/93081-tacoma-super-duty-transmission-mount.html

Solid motor mounts and transmission mounts
https://www.tacomaworld.com/threads...ted-solid-motor-mounts-for-sale.406631/page-4

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Installing an FJ transfer case and eliminate all the electronics - go manual stick shift
http://www.tacomaworld.com/forum/2nd-gen-tacomas/341459-fj-transfer-case-swap-work-2-7-a.html

Light up that 4x4 switch http://www.tacomaworld.com/forum/rcbs204/68173-rcbs204-4x4-illuminated-switch.html

Converting to solid axle and looking for parts ?
http://www.lowrangeoffroad.com/yotamain/inchwormgear/dana-60-flange-for-toyota-driveshaft.html

How to light the switch yourself http://www.tacomaworld.com/forum/li...4-switch-illumination-step-step-write-up.html

2 LOW MODULE ( NEW JAN / 2018 )
https://www.tacomaworld.com/threads/2lo-module-new-product.528488/

2 low mod and here at Tacoma World
https://www.tacomaworld.com/threads/2wd-lo-mod.195424/

Grey wire mod . this mod will let you use the locker in 2wd 4hi and 4 lo insted of just 4lo
http://www.tacomaworld.com/forum/1st-gen-tacomas/4405-grey-wire-mod.html

4LO-Trac & ABS Kill Switch

http://www.tacomaworld.com/forum/tec...y-why-not.html

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A-TRAC/TRAC/AUTO LSD Explained
http://www.tacomaworld.com/forum/tec...nd-i-hope.html

TRACTION CONTROL 2009-2014
http://www.tacomaworld.com/forum/2nd...-2014-a-3.html

Replacing seals with pics ( write up ) Bad transfer case switch on a 2004
https://www.tacomaworld.com/threads...and-movement-from-front-diff-actuator.519580/

FIRST GENERATION TRANSFER CASES ....CHECK BELOW

https://www.tacomaworld.com/threads/1st-gen-transfer-case-identifcation-for-replacement-swap.753707/


No 4x4 on a 1999 Tacoma
https://www.tacomaworld.com/threads/99-tacoma-wont-engage-4x4.420607/


2000 Tacoma vaccuum controlled and no 4x4
https://www.tacomaworld.com/threads/4wd-vsv-harness.700899/

WHY IS THERE A BIG COUNTERWEIGHT HANGING OFF MY TACOMA
https://www.tacomaworld.com/threads/what-is-hanging-off-my-transfer-case.332600/page-2


More about the front output here for the early transfer case 1999 noisy in 4 low
https://www.tacomaworld.com/threads/transfer-case-noise-possible-loose-chain.480346/#post-14988595

Parts http://parts.villagetoyota.com/show...=1997&ukey_category=19382&ukey_driveLine=6094


Here is an excellent source for identifying your Tacoma Transfer case
http://www.4x4wire.com/toyota/faq/parts/

Manual locking hub conversion kit
https://www.tacomaworld.com/threads/manual-locking-hub-conversion-1250.511528/





Different forms of traction control available with your Tacoma
http://www.tacomaworld.com/forum/te...uto-lsd-explained-easy-understand-i-hope.html


Driveshafts used with your 4x4 truck
Front Propeller Shaft Assembly (For 4WD): Components, Removal
Front Propeller Shaft Assembly (For 4WD): Disassembly, Inspection, Reassembly
Front Propeller Shaft Assembly (For 4WD): Installation
Rear Propeller Shaft Assembly (For Regular Cab 4WD): Components, Removal
Rear Propeller Shaft Assembly (For Regular Cab 4WD): Disassembly, Inspection, Reassembly
Rear Propeller Shaft Assembly (For Regular Cab 4WD): Installation
Rear Propeller Shaft Assembly (For Access Cab 4WD And Double Cab 4WD): Components, Removal
Rear Propeller Shaft Assembly (For Access Cab 4WD And Double Cab 4WD): Disassembly, Inspection
Rear Propeller Shaft Assembly (For Access Cab 4WD And Double Cab 4WD): Reassembly
Rear Propeller Shaft Assembly (For Access Cab 4WD And Double Cab 4WD): Installation
Front Drive Shaft (For 4WD): Components
Front Drive Shaft (For 4WD): Removal, Disassembly, Reassembly
Front Drive Shaft (For 4WD): Installation


Want that vibration gone ?
Tom Woods driveshaft
https://www.tacomaworld.com/threads/single-piece-driveshaft-vibes-be-gone.475797/

Driveshaft boots https://www.northerndrivetrain.com/category/cat_misc_bootkits.html





Flange Yokes http://www.tacomaworld.com/forum/2nd-gen-tacomas/128328-flange-yoke-need-help-2.html

https://www.tacomaworld.com/threads/flange-yoke.503185/

Read what Spicer has to say about greasing your driveline
http://www2.dana.com/pdf/J3299-2-DSSP.PDF

Replacing universal joints ...Write up with pictures
https://www.tacomaworld.com/threads/replacing-u-joints-write-up.292123/page-2

Addind a double Cardan u joint to your 2nd gen driveshaft
https://www.tacomaworld.com/threads/double-cardan-drive-shafts.556071/page-3

I would suggest spraying all your splines with gluidecoat http://www.amazon.com/Bostik-GlideCote-formerly-TopCote-10-75/dp/B008F87IYK

Driveshaft parts http://parts.lakelandtoyota.com/sho...=1998&ukey_category=21645&ukey_driveLine=6725


I am going off topic a little here but the concern has been raised that many trucks are being delivered to you guys without a single drop of grease in your new driveline , low oil in the differentials and low oil in the transfer case and last but not least , under torqued u-bolts holding your rear axle stable .
The factory grease in your universal joints is only an assembly lube . Your driveline needs to be lubricated at every oil change . Make sure they greased your driveline when they sold you the truck . There will be traces of fresh grease on the universal joints
Read what Spicer has to say about greasing your driveline . I am certain that Spicer still has the Toyota contract . They make all your driveshafts
http://www2.dana.com/pdf/J3299-2-DSSP.PDF
Read what federal Mogul has to say http://aftermarket.federalmogul.com/en-US/Technical/Documents/Driveline FAQ's.pdf
Here is a write up to help you https://www.tacomaworld.com/threads/greasing-entire-drive-shaft-u-joints-5-zerks-total.56976/
If you cant see any grease zerks , you've got polypropylene universal joints . They are designed for 50,000 trouble free miles according to the seminars I have trained at .Here is a new write up with some 2016 trucks involved
https://www.tacomaworld.com/threads/check-your-u-joints.409042/page-2#post-11509086
If you do not own a grease gun , go buy one because you are going to need it
If you have a two piece driveshaft , reports are coming in there is a lack of lubricant on the splines of the slip and stub . Your truck will clunk when downshifting into first gear when cold . Takes a special lubricant
This stuff will work http://www.lowrangeoffroad.com/ptfe...-ford-motorcraft-xg-8-ml1167-31508-42027.html
And this stuff is said to be the best but pricey http://paceperformance.com/i-782162...bricant-high-temperature-c1-2-w-a-t-1-lb.html

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Carrier bearing issues ?
https://www.tacomaworld.com/threads/aftermarket-carrier-bearings-center-support-bearings.477991/

Axles used in your 4x4

Front Axle Hub (For 4WD And Pre-runner): Components
Front Axle Hub (For 4WD And Pre-runner): Removal, Disassembly, Reassembly
Front Axle Hub (For 4WD And Pre-runner): Installation
Rear Axle Hub Bolt: Removal, Installation
Rear Axle Shaft: Components
Rear Axle Shaft: Removal, Disassembly, Inspection
Rear Axle Shaft: Reassembly, Installation

Lockers and mods http://www.tacomaworld.com/forum/performance-tuning/326238-gears-lockers-bs-thread.html

Step by step removal of rear differential locker ( write up )
https://www.tacomaworld.com/threads...d-installation-of-e-locker-3rd-member.193828/

Step by step removal of front differential ( write up ) Identify your differential http://www.off-road.com/trucks-4x4/tech/toyota-differential-identification-18588.html

Axle code identification https://www.tacomaworld.com/threads/2005-2016-tacoma-axle-codes.408019/

Calculate your ratio

Model​

Year​

Type​

Shifter​

Found Behind​

Gear Reduction​

Splines​

Notes​

RF1A​

1980-1995​

Gear Driven​

Forward​

G52, G54, W56 (89-95), R151F (with bench seat)​

2.28​

21, 23 (behind R151F)​

Can be identified by the 7 bolt rear cover.​

RF1A​

1979-1991​

Gear Driven​

Top​

L43, L45, L50, L52, W56 (85-88), R151F (with bucket seats)​

2.28​

21, 23 (behind R151F)​

Can be identified by the 7 bolt rear cover.​

VF1A​

1988-1995​

Chain​

Top​

R150, G58​

2.57​

23 (behind R150), 26 (behind G58)​

Can be identified by the 5 bolt rear cover.​

VF2A​

1984-1989​

Chain​

Mechanical Linkage on Side​

A340F​

2.57​

???​

A340H​

1988-1995​

Chain​

Electronically Controlled​

A340H​

2.66​

???​

Hydraulic transfer case, transmission and transfer case cannot be seperated.

http://www.tacomaworld.com/forum/1st-gen-tacomas/365138-oem-gear-ratio-chart.html

Toyota RF1A
Manufacturer: Aisin Seiki
Number of speeds: Two
High: 1:1
Low: 2.28:1
Case (or housing) material: Aluminum
Front output drive type: Gear (passenger side drop)
Availability or aftermarket parts and support: High - Dual/triple case kits, low gears sets, twin stick kits, rear disconnect kits, chromoly output shaft
Input spline count: 21 or 23
Rear yoke: Fixed flange
Planetary gear: No
Output shaft spline count: 27
Shifter type: Mechanical and electrical
Length: ~12.75 inches (mount face-to-flange)
Commonly found in: Various '79-to-'95 Toyota Truck and '84-to-'85 4Runner



​

____________________________________________________________________
Toyota VF1A/VF2A
Manufacturer: Aisin Seiki
Number of speeds: Two
High: 1:1
Low: 2.57:1
Case (or housing) material: Aluminum
Front output drive type: Gear (passenger side drop)
Availability or aftermarket parts and support: Medium - Dual case kits, adapters
Input spline count: 23 or 26
Rear yoke: Fixed flange
Planetary gear: Yes
Output shaft spline count: 27
Shifter type: Mechanical or electrical
Length: ~12.5 inches (mount face-to-flange)
Commonly found in: Various '84-to-'95 Toyota Truck/4Runner/T-100

​

 

A write up of what exactly?

 

Great source for all of my driveline questions. Thank you for taking the time to research this.

 

I think that this thread is supposed to be specific to 2005+ units, correct? You may want to check over some of those links, which apply only to <=2004.

I.e., Superduty transmission mount, also the 2-low mod (that mod will freak out the 4wd ecu before you can get it in low). There are a couple of different 2-low mods for 2005+ that work, that one just isn't one of them.

This is the 2-low mod I favor; http://www.yotatech.com/f117/2wd-low-done-right-280421/
(benefit being that it maintains correct inputs to all ECUs, nothing freaks out, no warnings on the dash.)

Also, very nicely implemented "yellow wire mod": http://www.yotatech.com/f117/4l-trac-done-right-280412/

 

Thanks gearcruncher

 

Awesome list!

 

Excellant post.
Thank you for your efforts.
TOMB

 

My 4x4 does not work for shit

I’ve replaced the actuator, the 2 sensors/limit switches on the t case actuator

2H to 4H, truck will engage, but will NOT STOP blinking

4H to 2H, light will continue to blink, but not disengage

Very frustrated & I don’t know what else to do or troubleshoot.

Any info will help

 

Did they have a manual / automatic version of the transfer case in a second gen? Ive searched and not found anything. Different ratios? If trans is swapped out can I use same transfer case. Thanks!

 

Same case, should work fine but you'll need the correct input.

 

Thank you.

 

Are you just swapping trans? Like auto to auto/manual to manual?

 

Planning a Auto > Manual swap.

 

Make sure you have the correct input on the xfer case. The manuals have a 22 spline output on the trans, autos are 23.

I've got an xfer case from my 6spd for sale if you'd be interested. I swapped over to an FJ case.

 

What is the reason/ advantage to swapping to an FJ transfer case? I've read or heard something about this in the past but wasn't really sure what that deal was all about. -Thanks trying to educate myself-

 

I believe it is to remove the ADD motor from controlling the engagement of the transfer case. Which it’s an issue by Toyota knows they tend to go bad and are kinda spendy.

 

You get a manual shifting xfer case vs an electronic shifting case. The plastic gears are known to break and the actuators are known to fail. Same thing for the front differential. By swapping to an FJ case you remove several parts prone to failure for about the same cost as a new actuator from Toyota.

It shifts in and out of 4x4 nearly instantly and if you do the twin stick mod to the FJ case you can use the lower great reduction off the transfer case in 2wd. In a manual, I really enjoy that. Great for backing up a trailer. Or really anytime you just want to go slower without slipping the clutch.

 

Oho man... and boom, just like that -ANOTHER- Mod is added to my list... my wife is going to kill me... JK - she is a GOAT -

Okay, so this is all new to me so unless you have a preferred link to this twin stick mod to the FJ case /swap i'll start searching and researching this.

My front 4x actuator has failed long ago, and until I recently found a video of how to get it out, i've just put it off and not gone off road... I'm saving for that actuator now, and your so very correct, not a low cost OEM part. I've sort of dreamed of going to a manual front hub like my '75 Land Cruiser had back in high school... (I really wish I still had that truck!!)

 

More info here.