Transfer case modification success

[Razorback81 Advanced Member Find all posts View Profile Close Razorback81]

another question
i guess the lights in the dash still do their thing when in the appropriate gear? (centre diff light comes on when in the locked spot)

[adrian5800 Advanced Member Find all posts View Profile Close adrian5800]

i just looked and those numbers on all the seals & the selector parts are the same in the diagram for my vin number

anything else you would order ? roll pins ? gaskets?

did you just pull the transfer case of the rear of the box or did you pull the whole gearbox & transfer case out of the car?

There's no gaskets, you can order a couple of the roll pins just in case, I did for the price.
90254-05001 x2

You can do either, the transfer is pretty easy to remove from the gearbox, I did it on the garage floor on axle stands, the transfer weighs about 40kg and I had no trouble lifting it out and back in on a creeper. I'm not a big guy (65kg wringing wet).

When you put it back in, be careful the alignment dowels are in place between the gearbox and case. Also be careful to line it back up to so the seal in the back of the box doesn't get damaged.

The CDL light on the dash works as is did before the mod.

Cheers

[Razorback81 Advanced Member Find all posts View Profile Close Razorback81]

OK 1 of the transfers is the odd one
the 36316-60010 that shaft is different on the V6 transfer case (by the pics on Partsorg)
so question is which is which in the pic looking in the top of the box with your transfer still fitted?
1 item you widened the slot and added a bit on the length
the other you added the stop on,

which is the high low shaft ?
&
which is the centre lock shaft ?

i can buy the shaft for that car and most likely modify it in the same fashion just have to do it on the shaft is all

cheers James

[adrian5800 Advanced Member Find all posts View Profile Close adrian5800]

OK 1 of the transfers is the odd one
the 36316-60010 that shaft is different on the V6 transfer case (by the pics on Partsorg)
so question is which is which in the pic looking in the top of the box with your transfer still fitted?
1 item you widened the slot and added a bit on the length
the other you added the stop on,

which is the high low shaft ?
&
which is the centre lock shaft ?

i can buy the shaft for that car and most likely modify it in the same fashion just have to do it on the shaft is all

cheers James

Does this help? I'm not sure why when I attach pics full size they end up this small.






The 1GR transfer is a top shift by the looks of the parts diagram, you won't be able to mod the high low rail (the one with stop) as that butts onto the outside front face of the transfer to limit the rear most travel of the rail. On the 1GR one the shift gate is inside the transfer case. Need to rethink that one. The lock gate (the one widened) will be just the same mod.



Cheers

[Razorback81 Advanced Member Find all posts View Profile Close Razorback81]

thanks
cant quite see it as it is small
which is the left rail & which is the Right rail ?
on the lock unlock shaft is that the one with the new wide slot?

[adrian5800 Advanced Member Find all posts View Profile Close adrian5800]

..Continued

Modified gates




These lugs aren't the finished dimension, I waited until the transfer case was back out of the car to cut them to length.
I used 10mm square bar tool steel. The gates are manufactured from case hardened steel for durability and wear resistance. This gate isn't subject to much force in use, the shift rail moves the lock hub fork on a double spring arrangement for lock and unlock plus the detent spring and ball pressure. There aren't any real worries the mod will weaken the gate to the point it would fail. If that were to happen, the broken part wouldn't cause any issues because the gates and gear lever are in the transfer case adapter void, not the transfer case itself.

Stripping the box is pretty easy, though there are 3 synchro dogs in the high/low range synchro hub, that are held in place by 2 spring loaded rings which probably will fly apart when the front casing is removed. Lose one and you are up sh!t creek.





3 synchro dogs held in place by the 2 spring clips






Removal of the interlock pin and circlip. Remove one of the plugs on either side of the case, remove the spring and ball, lift the rail shaft and use a magnet to remove the pin. Drop the rail back in and refit the ball and spring. Seal the plug threads with silicon sealant.

[adrian5800 Advanced Member Find all posts View Profile Close adrian5800]

...Continued




Finished modified shift gates



Modified transfer gear stick housing for right spring bias



New gear shift pattern





I am sure this mod will interest some that have a 120 with this transfer case. If you would like further clarification of this mod I'm happy to help. The parts required are cheap, the modifications and welding to the shift gates required is not really for the backyard diy-er though. The transfer has to come out (obviously) and requires stripping down and reassembly. If you're handy on the tools and think you would like to attempt this or get your mechanic to do the work, I could modify the gates for a small fee for my time and materials. This mod is completely reversible - remove the box, strip, swap the shift gates back and refit the circlip and interlock pin (provided you still have the original parts).

Happy days!

Cheers
Adrian

[phant0maz Lurker Find all posts View Profile Close phant0maz]

Happy to find your thread. I am looking for a transfer case for a project. From your knowledge and research you did about VF4B ,can it be converted to double shift levers with possibilities to shift from 2wd and 4wd? And what is the possibility to lock the center differential /from a Prado model without an electronic button for CDL/ with a separate lever? Thank you in advance. One more thing, how strong this case is, what is the torque rating for it? Is it the same like the one in FJ Cruiser, I mean the components.

[adrian5800 Advanced Member Find all posts View Profile Close adrian5800]

Happy to find your thread. I am looking for a transfer case for a project. From your knowledge and research you did about VF4B ,can it be converted to double shift levers with possibilities to shift from 2wd and 4wd? And what is the possibility to lock the center differential /from a Prado model without an electronic button for CDL/ with a separate lever? Thank you in advance. One more thing, how strong this case is, what is the torque rating for it? Is it the same like the one in FJ Cruiser, I mean the components.

The VF4B transfer can be converted easily to double shift provided it is a forward shift type. The transfers in the petrol v6 models are top shift and have different rail arrangements. Prados in Aus that have VSC/traction control have the CDL actuated by an electric actuator and cannot easily be converted to manual shift though nothing is impossible. FJs use the same transfer with the 6 speed manual box and the autos use the VF2B part time transfer case.
It is a pretty strong transfer case using a chain drive to the front output as opposed to earlier transfers that used drop gears that were sometimes prone to failure (cases breaking).

This is a link to a twin stick mod on an FJ top shift transfer https://www.fjcruiserforums.com/foru...iser-case.html

[phant0maz Lurker Find all posts View Profile Close phant0maz]

I'm confused now. Don't we need the top shift type for manual shifting conversion? /Like the one in v6 Prado/
I've red different forums, where people convert Prado or FJ transfer cases to double shifts, but couldn't understand, how do they engage the CDL separately ,since there are 2 levers. Don't you need third separate lever, for the CDL?
Here we have many 3.0 D4D diesels, some with manual others with automatic transmissions. I can't find which t case they have. In the manual with the serial numbers there is everywhere 36000 serial number for the T case, but nothing like VF4B or the other types? Do you know a source with information about which type of t case in wich model is used? Thank you for your reply.

[adrian5800 Advanced Member Find all posts View Profile Close adrian5800]

I'm confused now. Don't we need the top shift type for manual shifting conversion? /Like the one in v6 Prado/
I've red different forums, where people convert Prado or FJ transfer cases to double shifts, but couldn't understand, how do they engage the CDL separately ,since there are 2 levers. Don't you need third separate lever, for the CDL?
Here we have many 3.0 D4D diesels, some with manual others with automatic transmissions. I can't find which t case they have. In the manual with the serial numbers there is everywhere 36000 serial number for the T case, but nothing like VF4B or the other types? Do you know a source with information about which type of t case in wich model is used? Thank you for your reply.

One lever is for the CDL the other lever is for high/low range. I don't understand why you think you need 3?

Depending on the market, some 120 prados came with the 5L or 3RZ engine and come with the part time VF2B transfer, as far as I know all the 1KD/1KZ/1GR came with the VF4B/M transfers. The 1GR has the the top shift like the FJs (with full time 4WD) and they are the same transfer case but with different shift rails. The VSC equipped vehicles still have the same basic VF4B but with the electric actuator mounted on the back with one rail on top for high low which is designated the VF4BM.

[phant0maz Lurker Find all posts View Profile Close phant0maz]

I see where the confusion came from. I was thinking one lever is for 2wd/4wd, and the other is for High/Low gears. Ok than, isn't it possible to switch between 2wd and 4wd mode with this case? I'm not going to use it in Prado, it will be with manual locking hubs.

[adrian5800 Advanced Member Find all posts View Profile Close adrian5800]

I see where the confusion came from. I was thinking one lever is for 2wd/4wd, and the other is for High/Low gears. Ok than, isn't it possible to switch between 2wd and 4wd mode with this case? I'm not going to use it in Prado, it will be with manual locking hubs.

The VF4B case is full time AWD/4WD. It has a torsen centre diff and using that with free wheel hubs won't work. You could lock the CDL and leave the hubs free but that would be pretty pointless. I would source a VF2B part time transfer from a hilux.

[phant0maz Lurker Find all posts View Profile Close phant0maz]

Ah, but that is strange. In this thread the guy is using a case from FJ and he converts it to 2wd/4wd.

https://www.toyota-4runner.org/4th-g...-build-24.html

[adrian5800 Advanced Member Find all posts View Profile Close adrian5800]

Ah, but that is strange. In this thread the guy is using a case from FJ and he converts it to 2wd/4wd.

https://www.toyota-4runner.org/4th-g...-build-24.html

I'd suggest they are using the part time transfer from an auto FJ (VF2A). They have a single stick originally that moves both 2WD/4WD and high low rails at the same time. They describe cutting off the lug on the gate that locks the movement of the two together so they can be operated individually.