Transfer Case: Removal & Installation Toyota Tacoma I facelift

INSTALLATION

Installation is in the reverse order of REMOVAL .

1. APPLY MP GREASE TO TRANSFER ADAPTOR OIL SEAL
2. AFTER INSTALLATION, DO ROAD TEST

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1. REMOVE VEHICLE SPEED SENSOR Torque: 11.5 N.m (115 kgf.cm, 8 ft.lbf)
2. w/ One Touch 2-4 selector system and A/T: REMOVE L4 POSITION SWITCH Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
3. w/o One Touch 2-4 selector system: REMOVE 4WD POSITION SWITCH Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
4. A/T: REMOVE NEUTRAL POSITION SWITCH Torque: 37 N.m (380 kg.fcm, 27 ft.lbf)
5. REMOVE PLUGS OF FRONT CASE Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) NOTE: At the time of installation, check the following items. The input shaft and output shafts rotate smoothly. Shifting can be made smoothly to all position.
6. REMOVE PROTECTOR Remove the 4 bolts and protector. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
7. 3RZ-FE A/T: REMOVE SHIFT GEAR HEAD No. 1 AND No. 2 Using a pin punch and hammer, drive out the 2 slot spring pins. Remove the 2 shift gear heads.
8. REMOVE FRONT BEARING RETAINER Remove the 5 bolts. Torque: 11.5 N.m (115 kgf.cm, 8 ft.lbf) NOTE: At the time of installation, apply liquid sealer to the bolts. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a plastic hammer, tap the front bearing retainer and remove it. NOTE: At the time of installation, please refer to the following items. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the front bearing retainer. Apply FIPG to the front bearing retainer (Scheme 29) FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
9. 3RZ-FE A/T: REMOVE UPPER COVER, 2 GASKETS AND OIL DEFLECTOR Remove the 4 bolts, upper cover, 2 gaskets and oil deflector. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) NOTE: At the time of installation, install a new gasket.
10. EXCEPT 3RZ-FE A/T: REMOVE CONTROL RETAINER, GASKET AND OIL DEFLECTOR NOTE: At the time of installation, install a new gasket. Remove the 4 bolts, control retainer, gasket and oil deflector. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) w/o One Touch 2-4 selector system: Remove the select return spring from the control retainer.
11. REMOVE FRONT COMPANION FLANGE NOTE: At the time of installation, stake a new lock nut. Using a chisel and hammer, loosen the staked part of the nut. Using SST to hold the flange, remove the companion flange lock nut. SST 09330-00021 Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf) Using SST, remove the companion flange. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
12. REMOVE REAR COMPANION FLANGE Remove the rear companion flange in the same way as the front companion flange. NOTE: At the time of installation, please refer to the following items. Front companion flange bolts are slim. Rear companion flange bolts are thick.
13. REMOVE EXTENSION HOUSING Remove the 5 bolts. Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) NOTE: At the time of installation, apply liquid sealer to the bolts. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a plastic hammer, tap the extension housing and remove it. NOTE: At the time of installation, please refer to the following items. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the extension housing. Apply FIPG to the extension housing (Scheme 32) FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
14. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR Remove the vehicle speed sensor drive gear. NOTE: At the time of installation, please refer to the following item. Make sure to install the drive gear in the correct direction. Using a magnetic finger, remove the ball from the rear output shaft.
15. SEPARATE FRONT CASE AND REAR CASE Remove the 12 bolts. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) Using a screwdriver, separate the front case and rear case. NOTE: At the time of installation, please refer to the following items. Shift the high and low sleeve to low side (rear side) and assemble the front case and rear case. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the rear case. Apply FIPG to the rear case (Scheme 33) FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
16. REMOVE STRAIGHT SCREW PLUG, SPRING AND LOCKING BALL Using a hexagon wrench, remove the 1 or 2 screws. Torque: 18.6 N.m (190 kgf.cm, 14 ft.lbf) NOTE: At the time of installation, apply liquid sealer to the plugs. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a magnetic finger, remove the 1 or 2 springs and balls from the holes.
17. W/ ONE TOUCH 2-4 SELECTOR SYSTEM: REMOVE HIGH AND LOW FORK SHAFT, SHIFT FORK AND SHIFT HEAD NO. 2 Mount the rear case in a vise. CAUTION: Be careful not to damage the sealing surface. Using a pin punch and hammer, drive out the 2 slotted spring pins. Remove high and low fork shaft, shift fork and shift gear head No. 2. NOTE: At the time of installation, please refer to the following items. Place the high and low shift fork into the groove of the clutch sleeve. Make sure to install the shift fork and shift gear head No. 2 in the correct direction.
18. W/O ONE TOUCH 2-4 SELECTOR SYSTEM: REMOVE FRONT DRIVE FORK SHAFT, SHIFT FORK, SPRING AND STOPPER Mount the rear case in a vise. CAUTION: Be careful not to damage the sealing surface. Using a pin punch and hammer, drive out the 2 slotted spring pins. NOTE: When the pin is removed from the front drive fork shaft, the shaft will spring loose if the pin punch is removed, so keep the pin punch inserted in the shaft hole. NOTE: At the time of installation, please refer to the following items. Use a pin punch and hammer, drive in the 2 slotted spring pins. When installing the pin in the front drive fork shaft, push the shaft towards the rear case and install the pin while the spring is compressed. Hold the front drive fork shaft in place by hand, when removing the pin punch. Remove the front drive fork shaft, shift fork, spring and stopper. NOTE: At the time of installation, please refer to the following items. Place the front drive shift fork into the groove of the clutch sleeve. Make sure to install the shift fork and stopper in the correct direction. w/o One Touch 2-4 selector system: Using a magnetic finger, remove the straight pin. NOTE: At the time of installation, please refer to the following item. Apply gear oil to the straight pin and insert it into the case hole.
19. w/ One Touch 2-4 selector system: REMOVE REAR OUTPUT SHAFT, DRIVEN SPROCKET, CHAIN AND FRONT DRIVE SHIFT FORK Remove the shift fork bolt. Torque: 24 N.m (240 kgf.cm, 17 ft.lbf) Using a snap ring expander, remove the snap ring. Using a plastic hammer, tap the rear case with pulling the rear output shaft, driven sprocket and front drive shift fork. NOTE: At the time of installation, please refer to the following items. Place the front drive shift fork into the groove of the clutch sleeve. Make sure to install the shift fork in the correct direction. If necessary, heat the rear case to about 50 - 80°C (122 - 176°F). Remove the chain.
20. W/O ONE TOUCH 2-4 SELECTOR SYSTEM: REMOVE HIGH AND LOW FORK SHAFT AND SHIFT FORK NOTE: At the time of installation, please refer to the following items. Place the high and low shift fork into the groove of the clutch sleeve. Make sure to install the shift fork in the correct direction.
21. REMOVE REAR OUTPUT SHAFT, DRIVEN SPROCKET AND CHAIN Using a snap ring expander, remove the snap ring. Using a plastic hammer, tap the rear case with pulling the rear output shaft and driven sprocket. NOTE: At the time of installation, please refer to the following item. If necessary, heat the rear case to about 50 - 80°C (122 - 176°F). Remove the chain.
22. W/ ONE TOUCH 2-4 SELECTOR SYSTEM: REMOVE ACTUATOR ASSEMBLY Using 2 screwdrivers and a hammer, remove the snap ring. Remove the 3 bolts and the actuator assembly. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) NOTE: At the time of installation, please refer to the following item. Coat a new O-ring with gear oil and install it to the actuator assembly. Remove the O-ring, 4WD position switch and snap ring from the actuator assembly. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
23. M/T: REMOVE SYNCHRONIZER RING FROM INPUT SHAFT NOTE: At the time of installation, please refer to the following items. Apply MP grease to the synchronizer ring. Align the synchronizer ring slots with the shifting keys, and install it on the high and low clutch hub.
24. REMOVE SEPARATOR WITH OIL STRAINER AND MAGNET Remove the 3 bolts and the separator with the oil strainer and magnet. Torque: 7.5 N.m (80 kgf.cm, 69 in.lbf)
25. REMOVE OIL PUMP BODY ASSEMBLY Remove the 3 bolts and the oil pump body assembly. Torque: 7.5 N.m (80 kgf.cm, 69 in.lbf)
26. REMOVE OIL PUMP DRIVE GEAR
27. REMOVE PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT Using a snap ring expander, remove the snap ring. Pull out the planetary gear assembly with the input shaft. NOTE: At the time of installation, please refer to the following item. If necessary, heat the front case to about 50 - 80°C (122 - 176°F).
28. REMOVE LOW GEAR SPLINE PIECE NOTE: At the time of installation, please refer to the following item. Be sure the end gap of the snap ring is not aligned with cutout portion of the planetary carrier. Using a screwdriver, remove the snap ring. Remove the low gear spline piece.
29. REMOVE NEEDLE ROLLER BEARING FROM INPUT SHAFT NOTE: At the time of installation, apply gear oil to the needle roller bearing.
30. REMOVE INPUT SHAFT STOPPER AND THRUST BEARING Using a snap ring expander, remove the snap ring. NOTE: At the time of installation, please refer to the following item. Select a snap ring that will allow 0.05 - 0.15 mm (0.0020 - 0.0059 in.) axial play. SNAP RING THICKNESS CHART Mark Thickness mm (in.) A 2.10 -2.15(0.0827-0.0846) B 2.15 -2.20(0.0846-0.0866) C 2.20 - 2.25 (0.0866 - 0.0886) D 2.25 - 2.30 (0.0886 - 0.0906) E 2.30 - 2.35 (0.0906 - 0.0925) F 2.35 - 2.40 (0.0925 - 0.0945) G 2.40 - 2.45 (0.0945 - 0.0965) H 2.45 - 2.50 (0.0965 - 0.0984) J 2.50 - 2.55 (0.0984 - 0.1004) K 2.55 - 2.60 (0.1004 - 0.1024) L 2.60 - 2.65 (0.1024 - 0.1043) M 2.65 - 2.70 (0.1043 - 0.1063) N 2.70 - 2.75 (0.1063 - 0.1083) P 2.75 - 2.80 (0.1083 - 0.1102) Q 2.80 - 2.85 (0.1102 - 0.1122) R 2.85 - 2.90 (0.1122 - 0.1142) S 2.90 - 2.95 (0.1142 - 0.1161) T 2.95 - 3.00 (0.1161 - 0.1181) U 3.00 - 3.05 (0.1181 - 0.1201) Remove the input gear stopper, thrust washer and ball. NOTE: At the time of installation, apply gear oil to the input gear stopper and thrust washer.
31. REMOVE INPUT SHAFT, THRUST NEEDLE ROLLER BEARING AND THRUST RACE
32. REMOVE PLANETARY RING GEAR NOTE: At the time of installation, please refer to the following item. Be sure the end gap of the snap ring is not aligned with the upper side of the case. Using a screwdriver, remove the snap ring. NOTE: At the time of installation, apply liquid sealer to the plug. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Remove the plug, spring and pin. Torque: 18.6 N.m (190 kgf.cm, 14 ft.lbf) NOTE: At the time of installation, please refer to the following item. Make sure to install the ring gear in the correct direction. Remove the planetary ring gear.
33. INSPECT SWITCHES Check that there is continuity between terminals as shown in «SWITCH CONTINUITY CHART»(ref-192088-S38377582562005092100000). SWITCH CONTINUITY CHART Switch Position Specified Condition Push Continuity Free No continuity If operation is not as specified, replace the switch.