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Transfer Unit: Removal

  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  2. RAISE VEHICLE 
    NOTE: Make sure that the vehicle is securely supported.
  3. REMOVE TRANSFER CASE PROTECTOR 
    1. Remove the 3 bolts and transfer case protector.
    Fig 1: Identifying Transfer Case Protector
    G04063134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: 28 N*m (290 kgf*cm, 21 ft.*lbf) 

  4. DRAIN TRANSFER OIL 
    1. Drain transfer oil (see TRANSFER OIL  ).
  5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY 
    1. Remove the front propeller shaft (See REMOVAL ).
  6. REMOVE REAR PROPELLER SHAFT ASSEMBLY 
    1. Remove the rear propeller shaft assembly (See REMOVAL ).
  7. REMOVE TRANSFER SHIFT LEVER ROD ASSEMBLY 
    1. Remove the clip, plate washer, wave washer and bushing, and disconnect the transfer shift lever rod.
    Fig 2: Identifying Transfer Shift Lever Rod Assembly
    G04063135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE BODY GROUND WIRE SUB-ASSEMBLY 
    1. Remove the bolt and disconnect the body ground wire from the transfer.
  9. REMOVE CROSSMEMBER 
    1. Support the transmission, as shown in the illustration.
      NOTE: Use a wooden block so not to damage the transmission oil pan.
    2. Remove the 8 bolts, 2 nuts and crossmember.
    Fig 3: Identifying Crossmember
    G04063136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) for bolt 

    74 N*m (750 kgf*cm, 54 ft.*lbf) for nut 

  10. DISCONNECT BREATHER HOSE 

    HINT:

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

    Fig 4: Assembling Clips
    G04063137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR 
  12. DISCONNECT TRANSFER INDICATOR SWITCH CONNECTOR 
  13. DISCONNECT MOTOR ACTUATOR CONNECTOR 
  14. JACK UP TRANSFER ASSEMBLY 
    1. Using a transmission jack, support the transfer.
  15. REMOVE TRANSFER ASSEMBLY 
    1. Disconnect the wire harness from the transfer.
    2. Remove the 6 transfer adaptor rear mounting bolts.
      Fig 5: Identifying Transfer Adaptor Rear Mounting Bolts
      G04063138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 69 N*m (700 kgf*cm, 51 ft.*lbf) 

    3. Pull out the transfer down and toward the rear.
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