Toyota Cressida and Van 1983-1990

Transfer Case

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REMOVAL & INSTALLATION





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Fig. Fig. 1 When removing the transfer case, place matchmarks on the differential and driveshaft flange, then remove the retaining bolts



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Fig. Fig. 2 Disconnect the transfer case indicator switch and speed sensor if equipped



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Fig. Fig. 3 Using pliers, disconnect then place aside the speedometer cable and ground strap



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Fig. Fig. 4 When removing the transfer case on automatic models, disconnect the vacuum hoses leading to the acuator



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Fig. Fig. 5 On manual transmission transfer case removal, disconnect the transfer control cable



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Fig. Fig. 6 Separate the front exhaust pipe from the manifold ...



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Fig. Fig. 7 ... then raise the transmission up enough to remove the weight from the rear mounting



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Fig. Fig. 8 Remove the rear engine mounting bolts ...



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Fig. Fig. 9 ... and the transfer case mounting bolts. Remove the transfer case assembly from the vehicle

  1. Disconnect the battery ground.
  2.  
  3. Raise and support the vehicle on jackstands.
  4.  
  5. Remove the transfer case protector. Drain the fluid.
  6.  
  7. Remove the rear driveshafts as follows:
  8.  
    1. Place matchmarks on the differential and the driveshaft flange.
    2.  
    3. Remove the 4 bolts, washers and nuts, disconnect the driveshaft from the differential.
    4.  
    5. Place matchmarks on the transfer case and the driveshaft flanges.
    6.  
    7. Remove the 4 bolts, washers and nuts, disconnect the driveshaft from the transfer case.
    8.  

  9. Remove the front driveshafts as follows:
  10.  
    1. Remove the 2 differential support bracket retaining bolts.
    2.  
    3. Remove the 4 bolts and nuts, disconnect the differential support member from the body.
    4.  
    5. Place matchmarks on the differential and the driveshaft flanges.
    6.  
    7. Remove the 4 bolts, washers and nuts, disconnect the driveshaft from the differential.
    8.  
    9. Pull out the driveshaft yoke from the transfer case and place a container under the extension housing to catch any oil that spills out.
    10.  

  11. Disconnect the shift cable from the transmission outer lever.
  12.  
  13. Disconnect the vacuum hoses from the vacuum actuator.
  14.  
  15. Disconnect the speed sensor and the 4WD indicator connectors.
  16.  
  17. Disconnect the speedometer cable, ground strap and transfer indicator switch wiring.
  18.  
  19. Disconnect the transfer control cable.
  20.  
  21. Disconnect the exhaust pipe clamp from the transmission case. Remove the exhaust pipe from the manifold.
  22.  
  23. Support the transmission with a floor jack. Raise the transmission slightly.
  24.  
  25. Remove the rear engine mounting bolt.
  26.  
  27. Remove the transfer case mounting. Remove the transfer case by pulling the transfer case toward the rear of the vehicle.
  28.  

To install:

  1. Install a new transfer case gasket to the transfer case adaptor.
  2.  
  3. Align the input shaft spline with the transmission output shaft and push the transfer case fully into position. Apply a suitable thread sealer to the first 2 front bolts. Install the bolts and torque them to 27 ft. lbs. (37 Nm).
  4.  
  5. Install the rear engine mounting bolt and torque it to 36 ft. lbs. (49 Nm).
  6.  
  7. Connect the exhaust front pipe to the exhaust manifold. Tighten the bolts to 46 ft. lbs. (62 Nm). Install the front exhaust pipe clamp to the bracket.
  8.  
  9. Connect the transfer control cable.
  10.  
  11. Connect the vacuum hoses to the vacuum actuator.
  12.  
  13. Connect the speedometer cable and ground strap.
  14.  
  15. Attach the transfer indicator switch and speed sensor connector.
  16.  
  17. Install the front driveshafts as follows:
  18.  
    1. Insert the yoke into the transfer case.
    2.  
    3. Align the matchmarks on the flanges and connect the flanges with the 4 bolts, washers and nuts. Tighten the bolts and nuts 31 ft. lbs. (42 Nm).
    4.  
    5. Connect the differential support member to the body with the 4 bolts, washers and nuts. Tighten the bolts and nuts 70 ft. lbs. (95 Nm).
    6.  
    7. Install the 2 bolts to the bracket. Tighten the bolts until they are snug.
    8.  

  19. Install the rear driveshafts as follows:
  20.  
    1. Align the matchmarks on the flanges and connect the flanges with the 4 bolts, washers and nuts. Tighten the bolts and nuts 54 ft. lbs. (74 Nm).
    2.  
    3. Connect the rear driveshaft to the differential by aligning the matchmarks on the flanges and connect the flanges with the 4 bolts, washers and nuts. Tighten the bolts and nuts 54 ft. lbs. (74 Nm).
    4.  

  21. Refill the transfer case with the proper lubricant.
  22.  
  23. Lower the vehicle and connect all the disconnected wiring.
  24.  
  25. Reconnect the negative battery cable.
  26.  
  27. Start the engine check the transmission fluid level and add as necessary. Road test the vehicle and check for leaks.
  28.  

 
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