Transfer Unit: Removal

M/T:
REMOVE TRANSFER SHIFT LEVER
NOTE:
- w/o One Touch 2-4 selector system:
  Shift the transfer shift lever to the H4 position.
- w/ One Touch 2-4 selector system:
  Shift the transfer shift lever to the H position and 2-4 selector switch OFF.
- At the time of installation, apply MP grease to the tip of the shift lever.
1. Remove the 2 bolts, 4 screws and rear console box.
2. w/o One Touch 2-4 selector system:
  Remove the 2 screws, transmission shift lever knob, transfer shift lever knob and front console box.
3. w/ One Touch 2-4 selector system:
  Remove the 2 screws, transmission shift lever knob, transfer shift lever knob and front console box, and disconnect the 2-4 selector connector.
4. Remove the 4 screws, shift lever boot and retainer.
5. Using pliers, remove the snap ring and pull out the transfer shift lever.
  
  Fig 1: Removing Snap Ring Using Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
A/T:
REMOVE TRANSFER SHIFT LEVER
1. Remove the 2 bolts, 4 screws and rear console box.
2. w/o One Touch 2-4 selector system:
  Remove the 2 screws, transfer shift lever knob and front console box.
3. w/ One Touch 2-4 selector system:
  Remove the 2 screws, transfer shift lever knob and front console box, and disconnect the 2-4 selector connector.
4. Remove the nut and washer, and disconnect the shift control rod.
  
  Fig 2: Removing Nut And Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
5. Disconnect the connector and remove the 8 screws and transmission shift lever assembly.
  
  Fig 3: Removing Screws And Transmission Shift Lever Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
6. Remove the shift lever.
  1. 3RZ-FE A/T:
    Using pliers, remove the snap ring and pull out the shift lever.
    
    Fig 4: Removing Snap Ring Using Pliers
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 5VZ-FE A/T:
    Using pliers, remove the snap ring and pull out the shift lever.
    
    Fig 5: Removing Snap Ring Using Pliers
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BREATHER HOSE
Disconnect the breather hose from transfer upper cover and transmission control retainer.

Hose depth: 13 mm (0.51 in.) or more
RAISE VEHICLE AND DRAIN TRANSFER OIL

Fig 6: Checking Transfer Case Fluid Level
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Oil grade: API GL-4 or GL-5

Viscosity: SAE 75W-90

Capacity: 1.0 liters (1.1 US qts, 0.9 lmp. qts)
REMOVE FRONT AND REAR PROPELLER SHAFT (See REMOVAL ) .
REMOVE CROSSMEMBER
1. Support the transmission rear side.
2. Remove the 4 set bolts of the engine rear mounting.
  Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
3. Disconnect the O-ring and remove the 4 bolts, nuts and crossmember.
  Torque: 72 N.m (734 kgf.cm, 53 ft.lbf)
REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the transmission.

Torque: 65 N.m (660 kgf.cm, 48 ft.lbf)
DISCONNECT VEHICLE SPEED SENSOR, HEATED OXYGEN SENSOR CLAMP AND TRANSFER INDICATOR SWITCH CONNECTORS.
REMOVE TRANSFER FROM TRANSMISSION
1. Remove the 8 bolts of the transfer adaptor mounting.
  
  Fig 8: Removing Bolts Of Transfer Adaptor Mounting
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 24 N.m (240 kgf.cm, 17 ft.lbf)
2. Pull out the transfer down and toward the rear.
  NOTE:
  Take care not to damage the adaptor rear oil seal with the transfer input gear spline.