Removal (Tacoma - 4WD)
- Manufacturer recommends removing transfer case and transmission as an assembly for servicing of clutch assembly. Disconnect negative battery cable.
- Remove front console box. Remove transmission shift lever boot retainer. Pull transmission shift lever boot upward. Place shop towel on shift lever cap located at top of transmission on transmission shift lever. See Figure.
- Press shift lever cap downward and rotate counterclockwise to remove from transmission. Remove transmission shift lever with shift lever cap from transmission.
- Shift transfer case shift lever to "H4" position (without one touch 2-4 selector system) or "H2" (with one touch 2-4 selector system). Remove snap ring and transfer case shift lever.
- Raise and support vehicle. Drain transmission and transfer case fluid. Remove drive shaft dust cover (if equipped). Place reference mark on drive shaft flanges for reassembly reference. Remove drive shafts as required.
- Disconnect vehicle speed sensor, back-up lights switch and 4WD position switch connectors. Remove oxygen sensor. Discard oxygen sensor gasket. Remove necessary front exhaust pipe components for removal of transmission and transfer case. Discard exhaust pipe flange nuts and gaskets. Remove clutch release cylinder with hose attached and secure aside.
- Support engine with hoist. Support transmission with transmission jack. Remove necessary crossmember components for removal of transmission and transfer case.
- On all models, remove rear engine mount. Raise transmission slightly and remove starter connectors and starter. Remove stiffener plates located between rear of cylinder block and transmission. Remove transmission mounting bolts. Remove transmission and transfer case assembly. Remove rear engine mounts and transfer case-to-transmission bolts. Separate transfer case from transmission.
- Place reference mark on clutch cover and flywheel for reassembly reference. Alternately loosen clutch cover bolts until spring tension is released. Remove clutch cover and clutch disc.
- Remove clutch release fork and clutch release bearing from transmission (if necessary). See Figure.