I am getting ready to remove my tcase and cannot figure out what tool to use to remove the upper bolt inside the tcase. See picture. I was able to get a17mm shallow socket on the lower bolt and loosened it right up. The upper bolt is. 8.8 and looks like it will take a 19mm socket but I do not have enough room to get the socket and wrench into the case. Will a 19mm box wrench work? Any and all suggestions will be greatly appreciated. The other 3 bolts look like they will come off with a 17mm socket.
What tool to use????
- Thread starter NodrogCD
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- transfer case
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The top bolt isn't OEM, so likely isn't JIS, which explains the head size difference.'
If a box end wrench fits, use it. Once it breaks loose, it should be easy to remove.
You may have to use an open end wrench, given the limited clearance. On a bolt head that large, it shouldn't be a problem.
If a box end wrench fits, use it. Once it breaks loose, it should be easy to remove.
You may have to use an open end wrench, given the limited clearance. On a bolt head that large, it shouldn't be a problem.
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Thanks for the quick reply. I see another trip to. Auto Zone in my future. Do you know if I need to remo e the backup light switch before pulling case of the transmission. Also, any suggestions for removing my trashed needle bearing?
That sucks that somebody removed the OEM JIS bolt and replaced it with a larger head DIN bolt. It makes removing an already difficult bolt even harder. You really don't have too many options besides taking a 19mm open end wrench and trying to turn a little at a time. They typically spin easily once cracked. You can try grinding down your wrench a little to provide more clearance in there.
FYI if you have a 3/4" open end wrench it might save you trip to Auto Zone. No one has said it yet but be sure get the correct bolt to save any headache in the future.
It's prolly red loctite-ed in 
Autozone won't have the bolt you need to replace this substitute.
Order up a replacement bolt right now. The Toyota part no. varies, 3 speed vs 4 speed tranny. Both appear to come with integral washer.
I believe the part numbers are accurate, but don't blame me if they're not! For comparison purposes, The replacement for the upper one should be the same dimensions as the lower one for the 3 speed. The 4 speed lower appears to be a little shorter (28 mm) vs 55 mm for the top one.
For 3 speed,
Toyota Part No.: 91619-61240 about $3 list @ dealer.
for 4 speed
Toyota Part No.: 91619-61255 about $2.20 list @ dealer
Your original post didn't seem to mention why you were removing the T-case...
Order up a replacement bolt right now. The Toyota part no. varies, 3 speed vs 4 speed tranny. Both appear to come with integral washer.
I believe the part numbers are accurate, but don't blame me if they're not! For comparison purposes, The replacement for the upper one should be the same dimensions as the lower one for the 3 speed. The 4 speed lower appears to be a little shorter (28 mm) vs 55 mm for the top one.
For 3 speed,
Toyota Part No.: 91619-61240 about $3 list @ dealer.
for 4 speed
Toyota Part No.: 91619-61255 about $2.20 list @ dealer
Your original post didn't seem to mention why you were removing the T-case...
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Cheater's notes:
Loosen and remove the internal bolts first so they do not take the load from the t-case.
Allen head bolts are easier to remove and typical of the lower bolt in an Orion (yes, I know it's not OEM). I have a short chunk of Allen wrench I use with my 1/4" drive ratchet to speed up the process if they're finicky, after they are broke loose.
Loosen and remove the internal bolts first so they do not take the load from the t-case.
Allen head bolts are easier to remove and typical of the lower bolt in an Orion (yes, I know it's not OEM). I have a short chunk of Allen wrench I use with my 1/4" drive ratchet to speed up the process if they're finicky, after they are broke loose.