To adapt the t-case to the transmission I am using a combination of advance adapters products and custom adapter plates.
Starting at the back of the transfer case I am using the AA adapter plates for a 4L80 which adapt the split case to a 6 bolt round pattern:
buy 4L80E X TOYOTA L/C 19 SPLINE online
www.advanceadapters.com
Specifically these two items from the kit
buy TOY L/C FJ60 PLATE LARGE HOLE online
www.advanceadapters.com
buy ADAPTER- 4L80E TO TOYOTA 19 SPL online
www.advanceadapters.com
For the transmission side I am having custom adapters cut from 6061 aluminum, I measured out the bolt holes and drew these up in cad:
This bolts to the back of the transmission, I’ll get it cut from 3/8 which is the thickness of the raised circle around the output shaft:
View attachment 4062121
The next adapter will be cut from 3/4, this adapts the transmission pattern to the 6 bolt round pattern and has provisions for 7 and 14 degree clocking which should get the split case even with my frame rail. The holes will be threaded for m10x1.5 studs.
View attachment 4062122
The next adapter is just to make up whatever is left in thickness, still tbd
View attachment 4062123
I had the first adapter test cut out of 1/8 steel and I need to adjust two holes slightly. I also don’t like how close the clocking holes are to each other so I’m going to add a couple dowel pins to the assembly.