ADVANCE ADAPTERS INC. P/N: 50-5905D
P.O. Box 247, 4320 Aerotech Center Way
Paso Robles, CA 93447 PAGE 1 OF 9
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 08-10-09
TX2 CRAWLER ADAPTER
TOYOTA 4WD TRUCKS 21T INPUT
KIT CONSISTS OF:
No. Qty Part No. Description
1. 1 51-5909 TX2 ADAPTER CASTING
2. 1 52-5909 DOUBLE BEARING COUPLER
3. 11 716065 10mm X 1.25" X 48mm SPECIAL STUD
4. 1 716182 THRUST BUSHING
5. 1 716182A SPACER
6. 1 716182B 1/4" BALL
7. 1 716186 SPEED-O BUSHING
8. 2 716308 ROLLER BEARING
9. 1 716323 NEEDLE BEARING FOR CLUSTER GEAR
10. 1 716456 SNAP RING (T/A #N5000-334)
11. 1 716463 SNAP RING
12. 1 716563 GASKET
13. 1 716564 GASKET
14. 11 720012 10mm X 1.25" NUT
15. 11 720015 10mm FLATWASHERS
16. 11 720038 10mm LOCKWASHERS
17. 1 911069 KEY STOCK
18. 1 TT001 TOYOTA TRUCK INSTRUCTION MANUAL
Suggested Tools
Ratchet with a 12MM, 14MM, & 30MM sockets
Needle nose pliers
Snap ring pliers
6MM allen wrenches
Hammer
3/16" punch
Straight screw driver
Cresent wrench
Loctile
Assembly lube
OPTIONAL ITEM:
We now offer a custom 12" speedometer
extension for the crawler boxes. This
extension comes with both size drive
cogs to fit your stock or replacement
transfer case P/N 716186-C.
NOTE:
On 1979/80 transfer cases, the input shaft
was odd because it did not have a standard
spline relief as did all other Toyota 21 spline
gear-driven transfer cases. On these transfer cases, some grinding is required on the
input shaft for proper fit on this kit.
PREPARATION OF THE GEAR BOX
Disassemble the extra transfer case gear box using the instruction on the following pages.
SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion,
we strongly recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter
components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment.
These manuals are normally available at automotive dealerships and parts stores.
ADVANCE ADAPTERS INC. P/N: 50-5905D
P.O. Box 247, 4320 Aerotech Center Way
Paso Robles, CA 93447 PAGE 2 OF 9
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 08-10-09
TX2 CRAWLER ADAPTER
TOYOTA 4WD TRUCKS 21T INPUT
DISASSEMBLY PROCEDURES
The Advance Adapters TX2 crawler kit is ideal for the avid Toyota Truck rock crawler. The installation of the TX2 requires you to
almost completely disassemble the donor transfer case. We have provided illustrative disassembly and assembly instructions to assist you. These instructions are to be used as a guide. The official Toyota shop manual is strongly recommended
for additional information.
(1) The transfer case must be in 2WD High before
starting the disassembly procedures.
nut with a 30mm socket and then remove the flange.
(2) Remove the 7 bolts that retain the rear extension housing
with a 14mm metric socket.
SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion,
we strongly recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter
components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment.
These manuals are normally available at automotive dealerships and parts stores.
Remove the
(3) With the rear extension housing removed, you will see
the oil pump and speedometer drive gears. Slide the
gears off of the rear output shaft.
(4) Remove the rear output shaft bearing.
ADVANCE ADAPTERS INC. P/N: 50-5905D
P.O. Box 247, 4320 Aerotech Center Way
Paso Robles, CA 93447 PAGE 3 OF 9
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 08-10-09
TX2 CRAWLER ADAPTER
TOYOTA 4WD TRUCKS 21T INPUT
(5) Remove outer bearing C-clip by reaching inside case and
pushing up on gear, while lightly tapping on the case with
a plastic soft blow mallet.
(6) Remove the 10 bolts retaining the rear case cover with a
14mm socket.
(8) Using a 3/16" (4mm) punch, drive the roll pin out that
holds the front wheel drive shift fork.
(9) Slide the fork and clutch sleeve off the shift rail.
(7) Pull case off. Remove the two lubrication tubes located on
either side of the main shaft.
SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion,
we strongly recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter
components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment.
These manuals are normally available at automotive dealerships and parts stores.
Note their orientation!
(10) Remove the front wheel drive gear and it's caged
needle roller bearing assembly.
ADVANCE ADAPTERS INC. P/N: 50-5905D
P.O. Box 247, 4320 Aerotech Center Way
Paso Robles, CA 93447 PAGE 4 OF 9
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 08-10-09
TX2 CRAWLER ADAPTER
TOYOTA 4WD TRUCKS 21T INPUT
(14) Drive the roll pin out that
retains the high/low shift
fork using a 3/16" (4mm)
punch. Occasionally the
pin will fall into the case.
Don't worry. You will be
able to retrieve the pin
later. On 1979-83 and
1985-88 fuel injected
model transfer cases,
DO NOT REMOVE roll
pin.
(11) Remove the thick spacer found behind the front wheel drive
gear and be aware of the small ball bearing underneath it.
(12) Use a 12mm socket to remove the four bolts that retain the
shift fork cover. With a 6mm Allen wrench, remove the shift
detent screw plugs found on both sides of the case.
(13) With the screw plugs removed, the shift ball and spring
assemblies can be removed from both sides.
(15) Remove the shift
rails, being careful
not to lose the interlock pin that might
fall out.
This interlock pin is located between the two
shift rail detent assembly chambers.
(16) Remove the 4WD in-
dicator switch with a
22mm or adjustable
wrench.
SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion,
we strongly recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter
components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment.
These manuals are normally available at automotive dealerships and parts stores.
ADVANCE ADAPTERS INC. P/N: 50-5905D
P.O. Box 247, 4320 Aerotech Center Way
Paso Robles, CA 93447 PAGE 5 OF 9
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 08-10-09
TX2 CRAWLER ADAPTER
TOYOTA 4WD TRUCKS 21T INPUT
(17) Remove the interlock
pin from the shifter
detent chamber, if you
haven't already done
so in Step 15.
(18) Use a 14mm socket to remove the 4 bolts that retain the
front case to the reduction case. Split the cases. Now you
can retrieve the roll pin that might have fallen in as noted
on Step 14.
(19) Remove the output shaft from
the front case by removing the
4 bolts with a 12mm socket.
Remove the bearing retainer
and snap ring.
(20) Remove the low range gear by removing the snap ring
that retains the roller bearing onto the rear shaft.
Press the roller bearing off of the shaft.
(21) Now that the roller bearing is removed, you will see
a spacer. Remove the spacer, the gear and needle
bearing.
SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion,
we strongly recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter
components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment.
These manuals are normally available at automotive dealerships and parts stores.
ADVANCE ADAPTERS INC. P/N: 50-5905D
P.O. Box 247, 4320 Aerotech Center Way Old Part No: MC03
Paso Robles, CA 93447 PAGE 6 OF 9
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 08-10-09
TX2 CRAWLER ADAPTER
TOYOTA 4WD TRUCKS 21T INPUT
The low gear and needle bearing must then be installed onto the new shaft supplied. The
new thrust bushing and 1/4" ball will need to be placed on top of the output gear as
illustrated.
The new roller bearing will need to be installed into the
adapter housing and retained by the snap ring provided.
One of the thrust bushing gets placed in the housing and
then the second bearing is then pressed into the adapter
housing. We have also included a new caged needle
bearing that needs to be installed into the adapter housing
for the cluster gear support.
The first bearing is pressed in
and retained with a snap ring. A
thrust washer is placed on the
bearing and the second bearing is
pressed into the casting.
The shift fork or shift rod for the
reduction box must be modified. A
key stock has been provided to be
welded to the shifting component.
This has to be done because this is
the only shift rod retained in the
crawler box.
With the proper end play determined, the new shaft, gear, thrust bushings all in position & assembled into the new adapter,
and the shifter modifications made, you can now assemble this assembly on the reduction gear box. Make sure that the
new bearing has been installed for the counter shaft. Make sure that the shifter ring and fork are in the proper location
and the pocket needle bearing is installed in the output shaft.
leave the new shaft assembly standing upright on the work bench and install the casting with
the roller bearings on to the shaft assembly. The spacer washer between the bearing may
need to be alined with the bearing bores so as to allow the shaft to be slipped fully into the
casting assembly. This shaft assembly is a light press fit. Once the shaft is installed through
the bearings then install the small snap ring on the shaft. This snap ring will prevent the
output shaft from traveling forward. Make sure the gear has the proper end play .007-.010".
We have included 11 stud bolts, lock washers, flat washers,
and nuts. Six (6) of these fasteners are for the front of the full
transfer case and five (5) of them are for the crawler box.
The transfer case shift rod
should be shortened slightly to prevent any interference with
the reduction gear box shifter rod. Cutting the chamfered
portion off of this rod is normally sufficient.
(circled)
on the full transfer case
SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the components
will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion, we strongly
recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter components.
We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment. These manuals
are normally available at automotive dealerships and parts stores.
ADVANCE ADAPTERS INC. P/N: 50-5905D
P.O. Box 247, 4320 Aerotech Center Way Old Part No: MC03
Paso Robles, CA 93447 PAGE 7 OF 9
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 08-10-09
TX2 CRAWLER ADAPTER
TOYOTA 4WD TRUCKS 21T INPUT
INSTALLATION OF THE GEAR BOX
When installing the additional reduction gear box into your Toyota truck, you will need to make sure that the truck is
properly secured for transfer case removal. Once the vehicle is secured, both of the existing driveshafts will need to be
removed along with the crossmember and transfer case. With the transfer case removed, the back side of the 5 speed
transmission can then be inspected for the installation of the new reduction gear box. The output shaft should be 21 spline
and should index perfectly into the Toyota reduction box. Make sure that the seal and the splines are properly fitted
together.
With the new crawl box now in position, you can now assemble the transfer case back to the transmission and reduction
box assembly. If the front driveshaft does not interfere, the original crossmember can remain in its original location.
Vehicles with a 4" plus suspension lift or long front shackles will require some crossmember clearance modifications.
Lengthen the 4WD indicator light and install a new speedometer extension cable is
necessary for this conversion. We have provided a special bushing that can be used
to manufacture a speedometer cable extension. This bushing will need to be
furnished to your local cable manufacturer for the new 12 inch extension. We also
offer a custom speedometer extension, which is sold separately under P/N 716186-C.
Install the shifter levers for both the transfer case and the reduction box, making the necessary modifications to the
floorboard.
You will be required to lengthen the front driveshaft. If the truck is equipped with center support bearing on the rear
driveshaft, remove it and lengthen the driveshaft. Otherwise, shorten it as required.
The new crawl box and transfer case gear oil should be one and the same. We do not require any seal between the two
units. The same fill plug and oil level can be used.
SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion,
we strongly recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter
components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment.
These manuals are normally available at automotive dealerships and parts stores.
ADVANCE ADAPTERS INC. P/N: 50-5905D
P.O. Box 247, 4320 Aerotech Center Way Old Part No: MC03
Paso Robles, CA 93447 PAGE 8 OF 9
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 06-19-06
TX2 CRAWLER ADAPTER
TOYOTA 4WD TRUCKS 21T INPUT
SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion,
we strongly recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter
components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment.
These manuals are normally available at automotive dealerships and parts stores.
ADVANCE ADAPTERS INC. P/N: 50-5905D
P.O. Box 247, 4320 Aerotech Center Way Old Part No: MC03
Paso Robles, CA 93447 PAGE 9 OF 9
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 06-19-06
TX2 CRAWLER ADAPTER
TOYOTA 4WD TRUCKS 21T INPUT
P/N 50-5905 21 spline (4 cyl.)
P/N 50-5906 23 spline
(4 cyl. Turbo or V6)
This chart covers the 4 cylinder Gear-Driven Transfer Case (7 bolt rear cover)
VEHICLE APPLICATION
79 to 83
Carburated
85 to 88 EFI
84 to 88
Carburated
86 to 87 EFI
Turbo
89 to 95 EFI
Footnote #1 - The rear T/case must be a top shifting style (1979-83 Carbureted or 1985-88 EFI).
Footnote #2 - Reduction gear box can retain the original T/C shift rod location to match to the existing
transmission, or the reduction box can can be changed out to the 79-83 carbureted or
85-88 EFI box (T/C shift lever on reduction box).
Footnote #3 - Shift rods, forks & driveshaft flanges are interchangeable between all years shown.
TRANFER CASE SHIFTER BASE
LOCATION
Shifter on transfer case
4 Bolt Cast Iron Base
3-1/8" x 4-3/8"
Shifter on transmission tailhousing
4 Bolt Aluminum Base
3-1/4" x 4"
Shifter on transmission tailhousing
6 Bolt Aluminum Base
Transfer case & transmission s shift
handles are integral. Alum. base 4"x8"
DISTANCE
6 -1/2"
11"
10"
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