T SB 0149 10
T SB 0149 10
T SB 0149 10
Service
Category Drivetrain
Applicability
Introduction
Some 2010 model year 4WD Tacoma vehicles may exhibit a clicking or chirping noise from the
transfer case assembly when the vehicle is in motion. Production changes have been made to
eliminate this noise. Follow the procedure in the bulletin to correct this condition.
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown below.
MODEL PLANT ENGINE WHEEL BASE PRODUCTION CHANGE EFFECTIVE VIN*
TMMBC 3TMLU4EN#AM045486
Long
NUMMI 5TEUU4EN#AZ721895
1GR-FE
TMMBC 3TMMU4FN#AM018093
Tacoma Super Long
5TEMU4FN#AZ721735
NUMMI Short 5TEPX4EN#AZ721517
2TR-FE
Long 5TEUX4EN#AZ721943
NOTE
This is a production-caused issue that will be present at low mileage. Vehicles that exhibit a similar
condition that began after 3,000 miles should NOT need this repair. Refer to the Repair Manual to
diagnose this issue on vehicles with greater than 3,000 miles and NO prior condition history for
transfer case noise.
Confirm noise is loudest from the rear transfer case output area.
Remove transfer case assembly.
Disassemble transfer case and R & R rear output shaft needle bearing.
Reassemble transfer case.
Install transfer case and confirm proper operation.
Warranty Information
APPLICABLE WARRANTY
This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicles in-service date.
Parts Information
* Non-reusable.
JSPSM06606
ChassisEAR (or equivalent) ADE 1
(JS Products)
NOTE
A mechanics stethoscope or similar tool may be used in place of ChassisEAR.
* Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
1 SST
1 SST
HINT
If necessary, tap the extension housing
sub-assembly with a plastic hammer to
remove it.
7. Remove the transfer extension housing type T oil seal using a screwdriver and hammer.
8. Remove the transfer output shaft washer.
9. Remove the transfer speedometer drive gear.
Using a magnetic finger, remove the speedometer drive gear ball.
HINT
If necessary, tap the transfer rear case with a
plastic hammer to remove it.
12. Remove the 2 snap rings from the shift forks. Figure 7. .
14. Remove the rear output shaft snap ring using a Figure 9. .
snap ring expander.
NOTICE
Be careful NOT to lose the 2 interlock pins.
17. Using a press and the SST, remove the transfer Figure 12. .
output shaft rear radial ball bearing.
SST: 09555-55010
1 SST
18. Remove the drive sprocket and replace the rear Figure 13. .
output shaft needle bearing.
NOTE
Lubricate the bearing with new transfer case
oil before installation.
1. Install the transfer output shaft rear radial ball Figure 14. .
bearing.
Using the SST and a press, install the output
shaft rear radial ball bearing with the output shaft
snap ring groove toward the rear. 1
2
SST: 09316-60011 (09316-00011, 09316-00071)
1 SST
2 Bearing
NOTE
The clearance measurement should be similar to the measurement taken in step
16 of the Transfer Case Disassembly procedure.
If the clearance exceeds 0.25 mm (0.0098 in.), replace the drive sprocket sub-assembly.
Figure 15.
3. Install the rear output shaft assembly, front drive chain, driven sprocket assembly, shift shaft, and
shift forks No. 1 and No. 2.
HINT
Install shift interlock pins in shift forks No. 1
and No. 2, then slide the shift shaft in place.
C. Install the rear output shaft assembly, front drive chain, driven sprocket assembly, shift shaft,
and shift forks No. 1 and No. 2 onto the transfer rear case.
NOTICE
Do NOT let the clutch sleeve or shifting key drop.
HINT
If necessary, heat the rear case to about 122 to 176F (50 to 80C).
4. Install the rear output shaft snap ring using a snap Figure 18. .
ring expander.
5. Install the shift shaft stopper with the bolt. Figure 19. .
1 SST
1 SST
1 FIPG
NOTE
Be sure to thoroughly clean and dry the
extension housing and transfer case
sealing surfaces prior to applying FIPG.
1 FIPG
13. Install the transfer output shaft companion flange Figure 28. .
oil seals.
Using the SST and a hammer, tap in new output
shaft companion flange oil seals (front and rear).
1
SST: 09950-60010-01 (09951-00320-01)
SST: 09950-70010-01 (09951-07100-01)
1 SST
14. Install the front and rear output shaft companion Figure 29. .
flange sub-assemblies.
1 2
A. Install the companion flange sub-assembly
(front side) onto the drive sprocket
sub-assembly.
B. Using the SST to hold the companion flange,
install a NEW companion flange lock nut.
SST: 09330-00021
Torque: 118 N*m (1203 kgf*cm, 87 ft*lbf)
1 Front
2 Rear
3 SST