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Swapping inputs on the FJ Cruiser T case

September 4, 2017

 Many of you Tacoma wheelers out there still want to shift your Tacoma on your own. Cool.  But you also want to shift the t case on your own as well.  Toyota, in all their infinite wisdom thought hey, why don't we put a manual transmission in this thing and let the folks shift it on their own but give it an electronic transfer case. 


Well, as many of you have found out that six speed transmission is not all it's cracked up to be and the transfer case is even worse.  The actuator gets dirty or wet and stops working and then you try to fix it and that just leads to a jammed shift rod inside the case and now your stuck in either 4wd or worse yet, your stuck in 2wd and your in the middle of no where staring at an obstacle that requires 4lo.  Thanks Toyota!


But we do have a solution for you.  The FJ Cruiser T case from the automatic transmission FJ.  It's a manual shifting transfer case so no electronics to worry about and it's strong as hell.  I've never seen one fail.


For the swap of the FJ Cruiser transfer case into your Tacoma follow this link.  FJ Cruiser t case into Tacoma


In this post we are just showing you what you'll need to do to your new FJ case to put it behind your six speed transmission.  If you need to see about the swap itself follow the link above.


No I know some of you will say, hey, the FJ Cruiser came with a six speed transmission too.  I'll just use that one.  We'll, it's not that easy.  You see, the six speed FJ Cruiser is a full time 4wd system.  The T case in that FJ does not have 2wd.  Plus it's longer than your T case because it has a locking center differential in it.  Not a good choice.


Your going to want the t case from the auto transmission FJ Cruiser and swap out the planetary gear sets. 


Or like some people doing the 2wd to 4wd conversion, you can get the input shaft from Toyota along with the front cover and seals and just swap those into your FJ Case as well.


So lets see what you'll need to do.


 First lets look at the two inputs because that is where all the work will be done.  The one on the left with the larger splines is the input from a six speed Tacoma.  Notice how much larger the input is and also the difference in the front covers.  The one on the right is from the automatic Tacoma and it has the coupler pulled off of the splines already. 


When you swap these planetary gearsets from one t case to the other you'll need to also swap the covers as well.


So lets pull this puppy out.  First you'll need to open the case. 

One of the most important things to do is make sure your in 2wd in this case.  If your in 4wd or 4lo and you pull this case apart there are three little keys that will fall out from the synchro gear and you'll wish you'd never seen them.  If you see one or all three of these keys fall out when you pull your case apart you'll need to put them back in.  We'll cover that later.  Just make sure you have that case in 2wd when you pull it apart.

 So first you'll need to pull the front output flange off.  It has a 30mm nut that you'll want to use a heavy impact on to get it off.  Take it off and you can go to the next step.