Hi all.

I have a blown transfer case in my '04 HSE and am looking at picking one up with 80K miles off an '03 from a recycler that seems to know their way around these vehicles.

However, the guy on the phone from the recycler asked me if I needed one with the "lever" or not.

I have no idea what he was referring to and neither did he -- he was just reading from their description in the database (it is apparently already off the vehicle and on the shelf).

Any idea what he may be talking about? The RAV doesn't say anything about different versions of the transfer case, only that the '03-'04 is different from the '99-'02 (presumably because the transmission is bigger in '03-'04).

Any guidance here before I go to pick up the transfer case would be helpful here.

Thanks.

 

2003 t-case does not have a central differential lock. 2004 does.

 

As I recall, the 03 has a CDL but no lever to engage it. Some have retrofitted the 03 to utilize the CDL but anyone jump in to correct me if I'm mistaken.

 

Late 02 and all 03 do not have the CDL guts installed. Avoid at all cost. Get one from a 99-01 or an 04. Or if the nose cone and CDL parts are good in your old case, you can swap them into a non-cdl case.

 

JoshD is correct. Not only does the '03 not have the lever, but the transfer case is not equipped with a locking case.
The nose swap from the current '04 case is definitely a possibility if it's still in good condition. That's what I did with mine from a '99.

 

Key difference is the CDL "nipple" option is completely missing in the 2003.

 

I'd kook for one out of an 04, the older version, 99/01 have some slight differences. I believe there are a couple extra sensors with harness and plug connections.

 

Wow, thanks everyone for the education. I could've made a big mistake, thanks for saving me from that.

As I believe that my problem in my transfer case is with the front driveshaft output and this appears to be the "nose cone" of which you speak, swapping it onto an '03 doesn't seem like a smart idea for me, right?

Guess I will have to keep an eye out for an '04 as I am not up for figuring out whatever "mids" are required to make a '99-'02 fit.

BTW, since it sounds like all you you have done a transfer case swap, how hard is it? One day to get it out, one day to get it back in? It seems like an awful lot of steps in the RAV..

Fortunately, I have a friend who has a lift at his ranch that I can tie up for a weekend or more. What does the transfer case weigh?

 

I stand corrected. Thanks guys!
That being said, I may have an 04 transfer case available from a donor truck in Las Vegas, NV. Ping me if you are interested and I can check on availability.

 

Not that hard but it is a lot of steps but two days seems reasonable. You might want to reseal the donor unit (order a gasket set) as it much easier to do that now that later. One man can lift the transfer case but you will want a transmission jack or something to keep it steady as you mate it to the transmission.