MC-14572 Taco Box HLP

[arloey]

I just got my Taco box for my Tacoma from Marlin. I checked marlins site for install guide they have some pics but no walk through. I did my best to put it together. I bolted it all up and found that maybe i did something wrong the new case wont bolt up tight to the trans about 1/16" from trans. The only way i could even get it to pull together was by finding some long bolts. Tightening them up in the place of the stock bolts till it was close enough to fit the stock bolts in. I couldn't get the splints to go on easily so i figured they were just tight. Got it all the wy up to 1/16" away. any one no what i did wrong or where i might find a walk through I would call marlin but there not opened.

[arloey]

ttt

[Rotnweim]

I just got my Taco box for my Tacoma from Marlin. I checked marlins site for install guide they have some pics but no walk through. I did my best to put it together. I bolted it all up and found that maybe i did something wrong the new case wont bolt up tight to the trans about 1/16" from trans. The only way i could even get it to pull together was by finding some long bolts. Tightening them up in the place of the stock bolts till it was close enough to fit the stock bolts in. I couldn't get the splints to go on easily so i figured they were just tight. Got it all the wy up to 1/16" away. any one no what i did wrong or where i might find a walk through I would call marlin but there not opened.
Here is what my instructions say, for installation of part #lv6-4cx 3.4 v6 transmission to gear-driven transfer case adapter plate - 5/95 Tacoma and 4runner.

Keep in mind, these instructions are what I was given approx 2 years ago, so it MAY have changed, but this is what my one page instructions read....

"Adapter Instructions"

1. After removing the 8 transmission to left hand front output, chain-driven transfer case bolts, remove the female coupler on the input gear. This is a press fit and requires a bearing splitter or careful grinding to remove. MAKE sure that BOTH dowel pins remain in the transmission to properly align the adapter plate.

2. Install the plate and gasket to the front of the replacement gear-driven transfer case housing using the fore "A" bolts, and the two "B" bolts Torque to 26-30 ft. lbs

3. Remove the old transmission output seal, lube the sealing lip and install the new supplied transmission output seal. Part #mc395811

4. Install the 23 spline coupler, tapered end first, until it bottoms on the transmission output shaft. (this is a snug fit). When properly installed, the coupler will protrude 2.5" from the end of the mainshaft.

5. Install the transfer case assembly and torque eight bolts to 15-15 ft.lbs. Remember to seal the lower two 8x1.25mm 12-socket head bolts.

NOTE: BE very careful to make sure that all four "B" bolts are installed in their proper place or adapter plate failure is certain.

Upon completion, seal the 4 crossmember mount to transmission bolt threads to prevent oil seepage.

Use the original 8 transmission to transfercase bolts to attach the Marlin Crawler to the front of your original transfercase.

use 80/90 wt GL5 gear oil or synthetic gear box oil such as red line. approx 1 quart of oil is required.

[banthis]

Clarification I just got the other day that had me all screwed up- the new rear output seal for the tranny is that barrel seal that "press" fits where the old seal was and rests in the front adapter.
If you try to use that double ended dildo seal and the tranny output seal your fucking up. I did it that way the first two times I installed and it just crushes that seal to hell and makes it extremely difficult, like you said, to get that last 1/4 inch.

In short, the only seal between the rear of the tranny and the front of the crawler is that silver barrel seal with a seal in one end and open on the other side (open end to tranny- seal to crawler).