Toyota Tundra 2001-06

Transfer Case Removal & Installation

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3.4L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transfer case oil.
  4.  
  5. Shift the transfer shift lever into the H4 position.
  6.  
  7. Remove or disconnect the following:

    Transfer case shift lever knob
     
    4 screws, transfer case shift lever boot retainer and the shift lever boot
     
    Snapring from the transfer case shift lever and the lever
     
    Breather hose from the transfer case
     
    Front and rear driveshafts
     
    Dynamic damper from the transfer case
     
    Crossmember from the rear of the transmission
     
    4 bolts and the engine rear mount from the transfer case adapter
     
    Vehicle Speed Sensor (VSS) connector
     
    Transfer Detection Switch (TDS) connector
     

  8.  
  9. Support the transfer case
  10.  
  11. Remove or disconnect the following:

    8 transfer case-to-transfer adapter bolts
     
    Transfer case
     

  12.  

To install:

  1. Install or connect the following:

    Transfer case
     
    Transfer case-to-transfer adapter bolts. Torque the 8 bolts to 17 ft. lbs. (24 Nm).
     
    Transfer Detection Switch (TDS) connector
     
    Vehicle Speed Sensor (VSS) connector
     
    Engine rear mount to the transfer case adapter. Torque the 4 bolts to 48 ft. lbs. (65 Nm).
     
    Crossmember to the rear of the transmission. Torque the 4 nuts/bolts to 53 ft. lbs. (72 Nm).
     
    Crossmember to the chassis. Torque the 4 bolts to 13 ft. lbs. (18 Nm).
     
    Dynamic damper to the transfer case. Torque the 2 bolts to 28 ft. lbs. (38 Nm).
     
    Front and rear driveshafts
     
    Breather hose to the transfer case to a depth of 0.51 in. (13mm) or more
     
    Snapring to the transfer case-s shift lever
     
    4 screws, transfer case shift lever boot retainer and the shift lever boot
     
    Transfer case shift lever knob
     

  2.  
  3. Refill the transfer case to the correct level.
  4.  
  5. Test drive the vehicle.
  6.  

4.0L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Shift the transfer case into 2WD.
  4.  
  5. Disconnect the negative battery cable. Drain the transfer case oil.
  6.  
  7. Disconnect the breather hose from the transfer case.
  8.  
  9. Remove the front exhaust pipe assembly.
  10.  
  11. Remove the front driveshaft assembly.
  12.  
  13. Remove the number three crossmember subassembly.
  14.  
  15. Disconnect the transfer case detection switches and motor actuator connectors.
  16.  
  17. Properly support the transfer case assembly, using the proper transmission jack.
  18.  
  19. Remove the eight transfer case mounting bolts and clamps.
  20.  
  21. Carefully pull the transfer case out from the transfer adaptor down and toward the rear.
  22.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the transfer case retaining bolts to 17 ft. lbs.
  4.  
  5. Be sure to fill the transfer case with the proper grade and type oil.
  6.  
  7. Start the engine and check for leaks.
  8.  
  9. Roadtest the vehicle.
  10.  

4.7L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transfer case oil.
  4.  
  5. Turn the touch select 2-4 switch ON .
  6.  
  7. Remove or disconnect the following:

    Breather hose from the transfer case
     
    Left and right exhaust pipes
     
    Front and rear driveshafts
     
    Crossmember from the rear of the transmission
     
    4 bolts and the engine rear mount from the transfer case adapter
     
    Vehicle Speed Sensor (VSS) connector
     
    Transfer Detection Switch (TDS) connectors
     
    Motor actuator connectors
     

  8.  
  9. Support the transfer case
  10.  
  11. Remove or disconnect the following:

    8 transfer case-to-transfer adapter bolts
     
    Transfer case
     

  12.  

To install:

  1. Install or connect the following:

    Transfer case
     
    Transfer case-to-transfer adapter bolts. Torque the 8 bolts to 17 ft. lbs. (24 Nm).
     
    Motor actuator connectors
     
    Transfer Detection Switch (TDS) connector
     
    Vehicle Speed Sensor (VSS) connector
     
    Engine rear mount to the transfer case adapter. Torque the 4 bolts to 48 ft. lbs. (65 Nm).
     
    Crossmember to the rear of the transmission. Torque the 4 nuts/bolts to 53 ft. lbs. (72 Nm).
     
    Crossmember to the chassis. Torque the 4 bolts to 13 ft. lbs. (18 Nm).
     
    Dynamic damper to the transfer case. Torque the 2 bolts to 28 ft. lbs. (38 Nm).
     
    Front and rear driveshafts
     
    Left and right exhaust pipes
     
    Breather hose to the transfer case to a depth of 0.51 in. (13mm) or more
     

  2.  
  3. Refill the transfer case to the correct level.
  4.  
  5. Test drive the vehicle.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Shift the transfer case into 2WD.
  4.  
  5. Disconnect the negative battery cable. Drain the transfer case oil.
  6.  
  7. Disconnect the breather hose from the transfer case.
  8.  
  9. Remove the front exhaust pipe assembly.
  10.  
  11. Remove the front driveshaft assembly.
  12.  
  13. Remove the number three crossmember subassembly.
  14.  
  15. Disconnect the transfer case detection switches and motor actuator connectors.
  16.  
  17. Properly support the transfer case assembly, using the proper transmission jack.
  18.  
  19. Remove the eight transfer case mounting bolts and clamps.
  20.  
  21. Carefully pull the transfer case out from the transfer adaptor down and toward the rear.
  22.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the transfer case retaining bolts to 17 ft. lbs.
  4.  
  5. Be sure to fill the transfer case with the proper grade and type oil.
  6.  
  7. Start the engine and check for leaks.
  8.  
  9. Roadtest the vehicle.
  10.  

Vf2a Transfer Case



This transfer case is to be used with the 3.4L engine.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transfer case oil.
  4.  
  5. Shift the transfer shift lever into theH4
  6.  
  7. Remove or disconnect the following:

    Transfer case shift lever knob
     
    4 screws, transfer case shift lever boot retainer and the shift lever boot
     
    Snapring from the transfer case shift lever and the lever
     
    Breather hose from the transfer case
     
    Front and rear driveshafts
     
    Dynamic damper from the transfer case
     
    Crossmember from the rear of the transmission
     
    4 bolts and the engine rear mount from the transfer case adapter
     
    Vehicle Speed Sensor (VSS) connector
     
    Transfer Detection Switch (TDS) connector
     

  8.  
  9. Support the transfer case
  10.  
  11. Remove or disconnect the following:

    8 transfer case-to-transfer adapter bolts
     
    Transfer case
     

  12.  

To install:

  1. Install or connect the following:

    Transfer case
     
    Transfer case-to-transfer adapter bolts. Torque the 8 bolts to 17 ft. lbs. (24 Nm).
     
    Transfer Detection Switch (TDS) connector
     
    Vehicle Speed Sensor (VSS) connector
     
    Engine rear mount to the transfer case adapter. Torque the 4 bolts to 48 ft. lbs. (65 Nm).
     
    Crossmember to the rear of the transmission. Torque the 4 nuts/bolts to 53 ft. lbs. (72 Nm).
     
    Crossmember to the chassis. Torque the 4 bolts to 13 ft. lbs. (18 Nm).
     
    Dynamic damper to the transfer case. Torque the 2 bolts to 28 ft. lbs. (38 Nm).
     
    Front and rear driveshafts
     
    Breather hose to the transfer case to a depth of 0.51 in. (13mm) or more
     
    Snapring to the transfer case-s shift lever
     
    4 screws, transfer case shift lever boot retainer and the shift lever boot
     
    Transfer case shift lever knob
     

  2.  
  3. Refill the transfer case to the correct level.
  4.  
  5. Test drive the vehicle.
  6.  

Vf2bm Model



This transfer case is to be used with the 4.7L engine.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transfer case oil.
  4.  
  5. Turn the touch select 2-4 switchON
  6.  
  7. Remove or disconnect the following:

    Breather hose from the transfer case
     
    Left and right exhaust pipes
     
    Front and rear driveshafts
     
    Crossmember from the rear of the transmission
     
    4 bolts and the engine rear mount from the transfer case adapter
     
    Vehicle Speed Sensor (VSS) connector
     
    Transfer Detection Switch (TDS) connectors
     
    Motor actuator connectors
     

  8.  
  9. Support the transfer case
  10.  
  11. Remove or disconnect the following:

    8 transfer case-to-transfer adapter bolts
     
    Transfer case
     

  12.  

To install:

  1. Install or connect the following:

    Transfer case
     
    Transfer case-to-transfer adapter bolts. Torque the 8 bolts to 17 ft. lbs. (24 Nm).
     
    Motor actuator connectors
     
    Transfer Detection Switch (TDS) connector
     
    Vehicle Speed Sensor (VSS) connector
     
    Engine rear mount to the transfer case adapter. Torque the 4 bolts to 48 ft. lbs. (65 Nm).
     
    Crossmember to the rear of the transmission. Torque the 4 nuts/bolts to 53 ft. lbs. (72 Nm).
     
    Crossmember to the chassis. Torque the 4 bolts to 13 ft. lbs. (18 Nm).
     
    Dynamic damper to the transfer case. Torque the 2 bolts to 28 ft. lbs. (38 Nm).
     
    Front and rear driveshafts
     
    Left and right exhaust pipes
     
    Breather hose to the transfer case to a depth of 0.51 in. (13mm) or more
     

  2.  
  3. Refill the transfer case to the correct level.
  4.  
  5. Test drive the vehicle.
  6.  

 
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