Transfer Unit: Removal

RAISE VEHICLE
NOTE: Make sure that the vehicle is securely supported.
REMOVE TRANSFER CASE PROTECTOR
Remove the 3 bolts and transfer case protector.

Fig 1: Removing Transfer Case Protector Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 28 N.m (290 kgf.cm, 21 ft.lbf)
DRAIN TRANSFER OIL

Fig 2: Identifying Oil Level And Fitter Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Oil grade: API GL-4 or GL-5

Viscosity: SAE 75 W-90

Capacity: 1.3 liters (1.4 US qts, 1.1 lmp. qts)

Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
REMOVE FRONT AND REAR PROPELLER SHAFTS (See REMOVAL )
DISCONNECT TRANSFER SHIFT LEVER ROD ASSEMBLY
Remove the clip, plate washer, wave washer and bushing, and disconnect the transfer shift lever rod assembly.

Fig 3: Disconnecting Transfer Shift Lever Rod Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT GROUND CABLE
Remove the bolt and disconnect the ground cable from the transfer.
REMOVE CROSSMEMBER
1. Support the transmission, as shown in Fig 4.
  
  Fig 4: Removing Crossmember Nuts And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Use a wooden block so not to damage the transmission oil pan.
2. Remove the 8 bolts, 2 nuts and crossmember.
  Torque:
  
  Bolt: 50 N.m (510 kgf.cm, 37 ft.lbf)
  
  Nut: 74 N.m (750 kgf.cm, 54 ft.lbf)
DISCONNECT BREATHER HOSE
NOTE: At the time of installation, assemble the clip to the position shown in the illustration.
DISCONNECT NO. 1 VEHICLE SPEED SENSOR, 3 TRANSFER INDICATOR SWITCH AND MOTOR ACTUATOR CONNECTORS
JACK UP TRANSFER SLIGHTLY
Using a transmission jack, support the transfer.

Fig 5: Disconnecting Breather Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER FROM TRANSMISSION
1. Disconnect the wire harness from the transfer.
  
  Fig 6: Removing Transfer Adaptor Rear Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 6 transfer adaptor rear mounting bolts.
  Torque: 69 N.m (700 kgf.cm, 51 ft.lbf)
3. Pull out the transfer down and toward the rear.