Toyota Tacoma 2002-06

Transfer Case Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the transmission and the transfer case.
  6.  
  7. Remove or disconnect the following:

    Transfer case with the transmission
     
    Breather hose from the transfer upper cover and the transmission control retainer, if equipped with an automatic transmission
     
    Rear engine mounting
     
    Dynamic damper
     

  8.  
  9. Remove the driveshaft upper dust cover and the transfer from the transmissions, as follows:
    WARNING
    Be careful not to damage the adapter rear oil seal with the transfer input gear spline.



    Dust cover bolt from the bracket
     
    Transfer case adapter rear mounting bolts
     
    Transfer case, by pulling it straight up and away from the transmission.
     

  10.  

To install:

  1. Install the transfer case and the driveshaft upper dust cover to the transmission with a new gasket, as follows:
    WARNING
    Take care not to damage the oil seal by the input gear spline.



    Shift the 2 shift fork shafts to the high 4 position
     
    Apply MP grease to the adapter oil seal
     
    New gasket to the transfer adapter
     
    Transfer case to the transmission.
     



    Transfer case adapter. Tighten the rear bolts to 27 ft. lbs. (37 Nm).
     
    Dust cover to the bracket. Tighten the bolt to 17 ft. lbs. (23 Nm).
     

  2.  
  3. Install or connect the following:

    Engine rear mount. Tighten the bolts to 19 ft. lbs. (25 Nm).
     
    Dynamic damper. Tighten the bolts to 27 ft. lbs. (37 Nm).
     
    Breather hose, if equipped with an automatic transmission
     
    Transfer case with the transmission to the engine
     

  4.  
  5. Fill the transmission and the transfer case with oil.
  6.  
  7. Test drive the vehicle and check the abnormal noise and smooth operation.
  8.  
  9. Recheck the fluid levels.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the transfer case oil.
  6.  
  7. Remove the four bolts and remove the transfer case lower protector.
  8.  
  9. Remove the transmission assembly.
  10.  
  11. Remove the eight transfer adaptor rear mounting bolts. Pull the transfer case straight up and remove it from the transmission.
    NOTE
    Take care not to damage the adaptor rear oil seal with the transfer case input gear spline.

  12.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the eight transfer case mounting bolts to 17 ft. lbs.
  4.  
  5. Be sure to fill the transfer case with the proper grade and type transmission fluid.
  6.  
  7. Start the engine and check for leaks, correct as required.
  8.  

 
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