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Transfer Unit: Removal

WARNING: This page is about a different car, the 2002 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise vehicle  .
    NOTE: Make sure that the vehicle is securely supported.
  2. Remove transfer case protector  .
    1. Remove the 3 bolts and transfer case protector.
      Fig 1: Locating Bolts For Removal Of Transfer Case Protector
      G01048928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  3. Drain transfer oil  .
    Fig 2: Displaying Oil Level
    G01048929Courtesy 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) 

  4. Remove front and rear propeller shafts  .
  5. Disconnect transfer shift lever rod assembly  .
    1. Remove the clip, plate washer, wave washer and bushing, and disconnect the transfer shift lever rod assembly.
      Fig 3: Locating Clip For Removal
      G01048930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Disconnect ground cable  .
    1. Remove the bolt and disconnect the ground cable from the transfer.
  7. Remove crossmember  .
    1. Support the transmission, as shown in Fig 4.
      Fig 4: Removing Crossmember
      G01048931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION: Use a wooden block so not to damage the transmission oil pan.
    2. Remove the 8 bolts, 2 nuts and crossmember.

      Torque: 

      1. Bolt: 50 N.m (510 kgf.cm, 37 ft.lbf) 
      2. Nut: 74 N.m (750 kgf.cm, 54 ft.lbf) 

  8. Disconnect breather hose  .
    NOTE: At the time of installation, assemble the clip to the position shown in Fig 5.
    Fig 5: Assembling Clip To Breather Hose
    G01048932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Disconnect No. 1 vehicle speed sensor, 3 transfer indicator switch and motor actuator connectors. 
  10. Jack up transfer slightly  .
    1. Using a transmission jack, support the transfer.
  11. Remove transfer from transmission  .
    1. Disconnect the wire harness from the transfer.
    2. Remove the 6 transfer adaptor rear mounting bolts.
      Fig 6: Locating Mounting Bolts For Removal
      G01048933Courtesy 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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