Troop carirer transfer case split in

Submitted: Wednesday, Jul 20, 2005 at 01:58
ThreadID: 24895 Views:1568 Replies:4 FollowUps:2
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does anyone know if there is a common fault with the transfer case in 1996 troop carriers

went for drive down road felt a thud kept driving 20 klm and started to smell
gear oil pulled over looked under car and found transfer case split right along bottom of it has that been problem for these models

thanks
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Reply By: Member - Davoe (Widgiemooltha) - Wednesday, Jul 20, 2005 at 02:28

Wednesday, Jul 20, 2005 at 02:28
only for those smashed up against rocks:0 Actually never seen one split and have driven plenty of 75s and 79s seen plenty leak though (seals)
AnswerID: 121243

Reply By: Member - John (Vic) - Wednesday, Jul 20, 2005 at 07:32

Wednesday, Jul 20, 2005 at 07:32
Thats a new one, I think its the same transfer case as used in the then 80 series if I'm not mistaken. (Stand to be corrected)

My understanding that its common for Toyota to have used largely same running gear through 75 / 80 series and 78-79 / 100 series today. So if the problem is prevalent in one model then normally would be seen in the other.

As Dave said, oil leaks in the older models but no split cases.

Maybe ask the question on here http://autos.groups.yahoo.com/group/troopyoz/

This the Troop Carrier Owners group.
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AnswerID: 121245

Follow Up By: Member - Davoe (Widgiemooltha) - Wednesday, Jul 20, 2005 at 20:43

Wednesday, Jul 20, 2005 at 20:43
pretty sure they are not the ame case. they hold about 3l of oil about 2wice that of an 80 series
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Reply By: Peter 2 - Wednesday, Jul 20, 2005 at 08:27

Wednesday, Jul 20, 2005 at 08:27
what used to happen on earlier troopies (1980's) was that the idler shaft would wear until the gear teath started to touch the inside of the case, eventually a tooth would break off (due to reduced contact area) and then it would in turn get caught between the case and the remaining gear punching a hole in the case.
Sounds like what might have happened in your case.
I'd imagine the vehicle has some k's on it and would/could have been making a bit of a whine for a while?
If tojo transfers start to whine it is best to rebuild at that point as it would usually only require bearings and seals. Leave the noise for too long and major reconstruction or replacement is in order.
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AnswerID: 121254

Reply By: PhilRob - Wednesday, Jul 20, 2005 at 22:10

Wednesday, Jul 20, 2005 at 22:10
I have a 1996 troop carrier, if you can keep driving it as you say then then something is still intacted inside for it to keep working, does it sound crunchy like
things are falling to bits in there ???, or has damage been done from the outside.
these have a bash plate under them, is this bent and pushed against transfer case.
Where does the slit start and end exactly,

AnswerID: 121381

Follow Up By: PhilRob - Wednesday, Jul 20, 2005 at 22:42

Wednesday, Jul 20, 2005 at 22:42
Also if the seal between the transfer case & gear box fails the transfer
case oil can end up in the gearbox which causes the transfer case oil level to run low or the transfer case was a leaker and was never filled
up ???.
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