How to disassemble the transfer case on Toyota Tundra?

Question

Accepted Answer

The first step to disassemble the transfer case involves taking out the vehicle speed sensor assembly together with its bolt and O-ring followed by clipping off the driven gear. The transfer L4 position switch removal along with its gasket from M/T (with Diff. lock or ABS) and A/T requires 37 Nm (380 kgf-cm, 27 ft. lbs.) torque when installing a new gasket for reassembly. The next step involves removing the transfer 4WD position switch and gasket according to those specified torque values yet withholding the same procedure for the A/T transfer neutral position switch and gasket. Direct the technician to evacuate two plugs with their accompanying gaskets through the front case because this step helps the input and output shafts perform smoothly when reinstalling the system. Remove the protector through a process of four bolt removal with 18 Nm (185 kgf-cm, 13 ft. lbs.) torque. To remove shift gear heads No. 1 and No. 2 on A/T you must drive out two slotted spring pins before removing the heads. The process begins by detaching the front bearing retainer through five bolts tightened at 11 Nm (115 kgf-cm, 8 ft. lbs.). After threading the bolts with liquid sealer apply a plastic hammer to separate the retainer. M/T requires the pop-out of four bolts operating at 18 Nm torque (185 kgf-cm, 13 ft. lbs.) to free control retainer along with deflector and release select return spring while A/T needs removal of upper cover coupled with deflector by getting rid of four bolts each. The removal of upper cover and oil deflector requires you to detach four bolts along with two gaskets by applying identical torque specifications. Lifting the vehicle and securing it on dolly stands in a safe work area in alignment level to within one inch for each 150cm along the floor is essential before proceeding. The front companion flange removal process begins with unstaking the companion flange nut using a chisel and hammer followed by torqueing the Special Service Tool: 09330-00021 to hold the flange. The companion flange lock nut must be removed carefully with at least 118 Nm (1,200 kgf-cm, 87 ft.lbs.) torque using Special Service Tool: 09950-00011 (or any acceptable equivalent The operation to remove the rear companion flange includes the same removal steps but requires attention to the alternating bolt thickness. Detach the extension housing by first removing five bolts with 12 Nm (120 kgf-cm, 9 ft. lbs.) torque then finish the removal using a plastic hammer. The vehicle speed sensor drive gear with its washers should be removed before the front and rear case separation using twelve bolts at 28 Nm (285 kgf-cm, 21 ft. lbs.) plus a screwdriver. Unscrew and remove the straight screw plug and its spring along with the locking ball under a hexagon wrench torque of 19 Nm (190 kgf-cm, 14 ft. lbs.). Keep the pin punch in place while extracting the front drive fork shaft along with its shift fork and spring and stopper. After using a snap ring expander with a plastic hammer the technician should remove the rear output shaft assembly and the driven sprocket assembly together with the chain. M/T requires the removal of the input shaft's synchronizer ring for which you should use MP grease during assembly. The oil pump body assembly must be detached through separator removal with oil strainer and magnet after using a torque wrench of 7.5 Nm to loosen the three bolts. Reassemble the parts in correct order while aligning snap ring gaps properly. The procedure includes removal of the oil pump drive gear, planetary gear assembly with input shaft assembly and low gear spline piece. Start by removing the needle roller bearing from the input shaft assembly and input gear stopper and thrust bearing and race. Then remove the planetary ring gear yet apply liquid sealer to plugged threads with 19 Nm torque (190 kgf-cm, 14 ft. lbs.) and set snap ring gaps correctly. The inspection of the switch should follow to determine if replacement is needed.

OEM Toyota Transfer Case

141 Transfer Cases found

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case

Toyota Transfer Case Parts Questions & Experts Answers

Related Toyota Parts

Browse Toyota Transfer Case by Models