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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.

      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 ).
      Fig 1: Removing Bolts Of Transfer Case Protector
      G04437019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE TRANSFER SHIFT LEVER ROD ASSEMBLY 
    1. Remove the clip, plate washer, wave washer and bushing, and disconnect the transfer shift lever rod.
  8. REMOVE BODY GROUND WIRE SUB-ASSEMBLY 
    1. Remove the bolt and disconnect the body ground wire from the transfer.
      Fig 2: Removing Body Ground Wire From Transfer
      G04437020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CROSSMEMBER 
    1. Support the transmission as shown.
      NOTE: Use a wooden block so not to damage the transmission oil pan.
    2. Remove the 8 bolts, 2 nuts and crossmember.

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

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

      Fig 3: Supporting Transmission & Using Wooden Block
      G04437021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT BREATHER HOSE 

    HINT:

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

  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.
      Fig 4: Assembling Clip To Position
      G04437022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSFER ASSEMBLY 
    1. Disconnect the wire harness from the transfer.
    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.
      Fig 5: Removing 6 Transfer Adaptor Rear Mounting Bolts
      G04437023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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