Hey nice rig! Are the tyres 33s? They will hit your power with a cold spoon fore sure. I went from 31 inch to 32 inch not long after I had the motor installed and the change was very noticeable. It would have been even more noticeable if I had gone to 33.
I went through the same drama’s as you last year re: the electric transfer case. I ended up swapping in a manual TF case from a hilux as the wiring turned into a huge pain in the arse. I finally figured out a way to get the whole thing working using six 12v auto relays that used all the limit switches etc on the electric motor and case only to discover the electric motor soon burnt out. I don’t know wether that was because of my 12v relay system but maybe 12v is too much and the motor may need less than 12v to work? Don’t know. Couldn’t find any specs for voltages to this motor in any manual. Maybe someone else out there could shed some light on this. There is also a big plastic cog in the electric motor that warps if you supply power to the motor for too long, so it is important to use the limit switching (ie motor automatically turns off power when it reaches a certain point).
Rather than fork out $150 for another motor that may or may not fail I swapped in a hilux manual TF case, which cost about the same. That opened up another can o’worms. The output shaft on the A341LE and A340F compared to the input shaft on the manual hilux TF case were different diameters! Both cases had to be opened and the input shafts were swapped and this seemed to solve the problem. TF case goes great now.
I have to be in Neutral when I switch to 4wd, but this is a minor inconvenience in the scheme of things. When I shift it into 4L or 4H the driveline is dependant on a stick and some gearing and not that poxy electric motor at the back of the TF case.
Anyway, throughout the whole drama I found the following sites helpful.
http://www.ncttora.com/fsm/2003/index.html (TF case stuff is three quarters of the way down the page. It says it is for 2001 and 2004 Tacomas but also says that it is for the A340F transmission and R150 and R150F GBox, I think the only difference between your case and the one in this manual is the front drive shaft is on the opposite (left/passenger) side….. but don’t quote me)
http://www.ncttora.com/fsm/2003/Repair_Manual/03tacoma/tr/ot24ssy/loca.pdf
http://www.ncttora.com/fsm/2003/Repair_Manual/03tacoma/tr/trou/pst.pdf
http://www.ncttora.com/fsm/2003/Repair_Manual/03tacoma/tr/ot24ssy/insp.pdf
Loads of manuals on this site:
http://forums.bauchan.org/portal/downloads.php, click on “Toyota Workshop & Repair Manuals” for 4runner/hilux workshop manuals.
There were some more but that is all I can remember at the moment.
Hope this helps…..