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.
1. Torque: 28 N.m (290 kgf.cm, 21 ft.lbf)
  
  Fig 1: Removing Bolts & Transfer Case Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DRAIN TRANSFER OIL
1. Oil grade: API GL-4 or GL-5
2. Viscosity: SAE 75 W-90
3. Capacity: 1.3 liters (1.4 US qts, 1.1 Imp. qts)
4. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)

Fig 2: Draining Transfer Oil

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

DISCONNECT GROUND CABLE
Remove the bolt and disconnect the ground cable from the transfer
REMOVE CROSS MEMBER
1. Support the transmission, as shown in Fig 4 .
  NOTE: Use a wooden block so not to damage the transmission oil pan.
2. Remove the 8 bolts, 2 nuts and cross member.
  1. Torque:
  2. Bolt: 50 N.m (510 kgf.cm, 37 ft.lbf)
  3. Nut: 74 N.m (750 kgf.cm, 54 ft.lbf)
DISCONNECT BREATHER HOSE
HINT:

At the time of installation, assemble the clip to the position shown in Fig 5 .

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