Toyota Pick-ups/Land Cruiser/4Runner 1970-1988

REMOVAL & INSTALLATION

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See Figure 1

The transfer case is removed as an assembly with the transmission.

  1. Remove the transmission assembly.
  2.  
  3. Remove the rear engines mount from the case.
  4.  
  5. Remove the upper driveshaft dust cover.
  6.  
  7. Remove the transfer adapter rear mounting bolts and then pull the transfer case straight up and remove it.
  8.  


CAUTION
Be careful not to damage the adapter rear oil seal during removal.

  1. Move the 2 shift forks into the HIGH-FOUR position.
  2.  
  3. Coat the adapter oil seal with grease and position a new gasket on the transfer case adapter.
  4.  
  5. Install the transfer case to the transmission. Tighten the bolts to 29 ft. lbs. (39 Nm). The longer bolts (43mm) are used at the dust cover, the shorter ones (39mm) are used in all other locations.
  6.  
  7. Install the rear engine mount and tighten the bolts to 19 ft. lbs. (25 Nm).
  8.  
  9. Install the transmission assembly.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Installing the transfer case assembly

OVERHAUL



See Figures 2 and 3

  1. Remove the front and rear companion flanges.
  2.  
  3. Remove the extension housing.
  4.  
  5. Remove the speedometer drive gear, steel ball, oil pump screw and bearing.
  6.  
  7. Remove the rear case half with the idler gear in position, while holding the front half so that the clutch hub and steel ball do not fall out.
  8.  
  9. Remove the idler gear from the rear case.
  10.  
  11. Remove the front bearing retainer and front drive gear.
  12.  
  13. Remove the 2 oil pipes.
  14.  
  15. Remove the No. 1 shift fork and clutch sleeve.
  16.  
  17. Remove the clutch hub and transfer drive gear. Remove the needle roller bearing, No. 2 spacer and steel ball. On models with the 22R engine, remove the transfer case cover and shift lever retainer.
  18.  
  19. Remove the screw cover plugs, springs and locking balls from both sides of the case.
  20.  
  21. Remove the spring pins that retain the shift forks and remove the front shift fork shaft. Remove the interlocking pin and high/low fork.
  22.  
  23. Remove the front case, tapping lightly with a plastic mallet.
  24.  
  25. Remove the No. 2 shift fork, clutch sleeve and needle roller bearing from the input shaft.
  26.  
  27. Remove the input gear and countergear from the reduction gear case. Remove the output shaft from the front case.
  28.  
  29. Check the oil seal and thrust clearance of the transfer low gear. The clearance between the gear and shaft, with the needle bearing installed, should be 0.010-0.056mm. The thrust clearance with the spacer and bearing installed should be 0.010-0.25mm.
  30.  
  31. Check the thrust drive gear clearance. Clearance between the gear and shaft with the needle bearing installed should be 0.010-0.050mm. Thrust clearance with the clutch hub and spacer installed should be 0.089-0.270mm.
  32.  
  33. Measure the clearance between the shift forks and clutch sleeves. Clearance should be 1mm max.
  34.  
  35. Inspect all parts. Replace any worn or damaged parts. If the bearings are to be replaced, you'll need an arbor press to remove and install them. When installing bearings, use the thickest possible snapring to insure minimum end-play.
  36.  

To assemble
  1. Place the output shaft in the front case.
  2.  
  3. Install the front bearing retainer and torque the bolts to 10 ft. lbs.
  4.  
  5. Install the input gear and countergear in the reduction case.
  6.  
  7. Install the roller bearing on the input shaft.
  8.  
  9. Install the No. 2 hub sleeve and No. 2 shift fork on the input shaft.
  10.  
  11. Install the reduction gear case and new gaskets on the front case. Torque the bolts to 30 ft. lbs.
  12.  

Two different length bolts are used. May sure you get them in the correct holes.

  1. Install the front drive gear, bearing retainer and new gasket. Torque the bolts to 14 ft. lbs.
  2.  
  3. Install the high/low shift fork, the interlock pin and front drive shift fork shaft.
  4.  
  5. Install the slotted spring pins. Install the balls, springs and side plugs. Tighten the plugs to 10 ft. lbs.
  6.  
  7. Install the locking ball and No. 2 spacer. Install the needle roller bearing, transfer low gear and clutch hub.
  8.  
  9. Install the No. 1 shift fork and hub sleeve.
  10.  
  11. Install the oil pipes.
  12.  
  13. Install the idler gear in the rear case.
  14.  
  15. Using anew gasket, install the rear case. Torque the bolts to 30 ft. lbs.
  16.  

Two different length bolts are used. May sure you get them in the correct holes.

  1. Install the bearing, oil pump screw, locking ball and speedometer drive gear.
  2.  
  3. Install the extension housing with a new gasket. Torque the bolts to 30 ft. lbs.
  4.  
  5. On trucks equipped with the 22R engine, install the transfer case cover and shift lever retainer.
  6.  
  7. Install the front and rear flanges. Torque the fasteners to 90 ft. lbs.
  8.  
  9. Install the indicator switch and speedometer driven gear.
  10.  



Click image to see an enlarged view

Fig. Fig. 2: Transfer case components



Click image to see an enlarged view

Fig. Fig. 3: Transfer case components

 
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