Transfer case chain

[bens313]

Hi All,

Unfortunately i think the transfer case chain is slipping under heavy load on my 2001 D-4D 90. When i try to make a hasty exit out of a junction or accelerate hard in 1st (Even in a straight line) i get a popping sound very similar to this video but maybe 3 or 4 pops: I also have slack when going on/off throttle low speed. CV's were done a year ago and all UJ's have been greased.

How much of a pain is changing the chain in these? I'm guessing i'm looking at £200 just for the part but if anyone knows the best place to get them, let me know.

Ben.

 

[bens313]

Also is the chain the same as the one for the 120? I can find examples of that everywhere but none for the 90. Its a manual.

 

[bens313]

Just thought id give a little update for anyone who looks at this in the future as its now done....

1. Toyota confirmed the chain is the same in the 90 as in the 120 transfer case. 90 part number is 36293-35031 and 120 part number is 36293-35040. If you are looking for a chain for the 90, just use the 120 part number as its much easier to find one. Manual and Auto use the same part.
2. Toyota wanted £700 for the part but if you keep an eye on eBay brand new genuine Toyota ones pop up from time for around £200. Mine was from the United Arab Emirates.
3. I first did this chain because a drive line shunt at low speed and low gears, also because it was slipping under load similar to the above video (not as bad) and when i bought the car the TC oil was low and coffee coloured. It has solved the slipping and 90% of the shunt. It had stretched about 20mm circumference compared to the new one!
4. I got my Mechanic to do it in the end, he did it with the case in the car and said it wasn't too bad but there are little balls and springs used in the shifter that were fiddly and he used a magnet to keep them in place.

Ben.