Transfer case removal instructions please!

Hi,

Honestly, I don't believe that is correct. Plus, you don't want to eliminate mounting points. If you need to cut a bolt, it's because of an access issue. So, that means it won't be replaceable.

Regardless, I feel the engine and transaxle needs pulled to do it correctly.

Here are the directions for removing the engine/transaxle and transfer case. The attached pics correlate with the directions.

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2007 Toyota Truck RAV4 4WD L4-2.4L (2AZ-FE)
Removal
Vehicle Engine, Cooling and Exhaust Engine Service and Repair Removal and Replacement Engine Assembly Removal
REMOVAL
ENGINE ASSEMBLY

COMPONENTS (Part 1)
pic 1

COMPONENTS (Part 2)
pic 2

COMPONENTS (Part 3)
pic 3

COMPONENTS (Part 4)
pic 4

COMPONENTS (Part 5)
pic 5

COMPONENTS (Part 6)
oic 6

COMPONENTS (Part 7)
pic 7

COMPONENTS (Part 8)
pic 8

COMPONENTS (Part 9)
pic 9

COMPONENTS (Part 10)
pic 10

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE HOOD SUB-ASSEMBLY
4. REMOVE RADIATOR SUPPORT OPENING COVER
5. REMOVE BATTERY CLAMP SUB-ASSEMBLY
(a) Loosen the bolt and nut, and remove the battery clamp.
6. REMOVE BATTERY
7. REMOVE BATTERY TRAY
8. REMOVE FRONT WHEEL
9. REMOVE NO. 1 ENGINE UNDER COVER
10. REMOVE NO. 2 ENGINE UNDER COVER
11. REMOVE FRONT FENDER APRON RH
12. REMOVE NO. 1 ENGINE COVER
13. DRAIN ENGINE COOLANT
14. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain automatic transaxle fluid for U241E (2WD).
(b) Drain automatic transaxle fluid for U140F (4WD).
15. REMOVE RADIATOR ASSEMBLY
(a) Remove the radiator.

Pic 11

16. REMOVE RADIATOR RESERVOIR
(a) Remove the 2 bolts and reservoir.
17. REMOVE PURGE VSV
18. REMOVE AIR CLEANER CAP
19. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

pic 12

20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
(a) Remove the 3 bolts from the air cleaner case.
(b) Disconnect the case from the NO. 1 air cleaner inlet.

Pic 13

21. REMOVE FRONT BATTERY CARRIER
(a) Disconnect the 2 clamps of the engine wire.
(b) Remove the 4 bolts and front battery carrier.

Pic 14

22. REMOVE BATTERY BRACKET REINFORCEMENT
(a) Remove the 2 bolts and battery bracket reinforcement.

Pic 15

23. REMOVE BATTERY CARRIER BRACKET
(a) Remove the 2 bolts, nut and battery carrier bracket.

Pic 16

24. DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a) Disconnect the 2 union to connector tube hoses from the booster vacuum tube.

Pic 17

25. DISCONNECT HEATER WATER INLET HOSE
(a) Disconnect the heater water inlet hose from the heater unit.

Pic 18

26. DISCONNECT HEATER WATER OUTLET HOSE
(a) Disconnect the heater water outlet hose from the heater unit.
27. DISCONNECT FUEL TUBE
28. REMOVE THROTTLE BODY
29. DISCONNECT NO. 2 VENTILATION HOSE
30. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
31. REMOVE INTAKE MANIFOLD
32. REMOVE INTAKE MANIFOLD INSULATOR
33. REMOVE TRANSAXLE CONTROL CABLE ASSEMBLY
(a) Remove the transaxle control cable for U241E (2WD).
(b) Remove the transaxle control cable for U140F (4WD).
34. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH
35. REMOVE FAN AND GENERATOR V BELT
36. REMOVE GENERATOR ASSEMBLY
37. REMOVE COOLER COMPRESSOR ASSEMBLY
(a) Remove the cooler compressor.

HINT: Disconnect the compressor together with the low-pressure and high-pressure hoses, then secure it to the vehicle side using rope.

38. REMOVE ECM
39. DISCONNECT ENGINE WIRE
(a) Remove the engine room relay block cover.

Pic 19

(b) Remove the nut and disconnect the 2 engine wire connectors.

Pic 20

(c) Remove the bolt and engine wire cover. Then disconnect the engine wire from the engine wire cover.

Pic 21

(d) Disconnect the ground cable connector.

Pic 22

(e) Remove the nut from the positive (+) battery terminal to disconnect the engine wire.

Pic 23

(f) Disconnect the ground cable from the clamp located near the starter.
(g) Remove the bolt and ground cable located near the starter.
40. REMOVE FRONT EXHAUST PIPE ASSEMBLY
41. REMOVE FRONT DRIVE SHAFT ASSEMBLY
(a) Remove the front drive shaft (for 2WD).
(b) Remove the front drive shaft (for 4WD).
42. REMOVE PROPELLER SHAFT ASSEMBLY (for 4WD)

pic 24

43. REMOVE ENGINE MOUNTING INSULATOR FR
(a) Remove the through bolt and nut.

Pic 25

(b) Remove the 2 bolts and engine mounting insulator FR.

Pic 26

44. REMOVE ENGINE MOUNTING INSULATOR RR
(a) Remove the through bolt.

Pic 27

(b) Remove the 2 nuts, 2 bolts and engine mounting insulator RR.

Pic 28

45. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the No. 1 and No. 2 engine hangers with the bolts as shown in the illustration.
Torque: 38 Nm (387 kgf-cm, 28 ft. Lbs.)

Part No.
Pic 29

pic 30

(b) Attach the sling device to the engine hangers and chain block.
(c) Carefully remove the engine with transaxle from the vehicle.

Pic 31

46. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the 2 nuts, 4 bolts and engine mounting insulator RH.

Pic 32

47. REMOVE ENGINE MOUNTING INSULATOR LH
(a) Remove the through bolt and nut.

Pic 33

(b) Remove the 4 bolts and engine mounting insulator LH.

Pic 34

48. REMOVE DRIVE SHAFT BEARING BRACKET (for 2WD)
(a) Remove the 3 bolts and bracket.

Pic 35

49. REMOVE DRIVE SHAFT BEARING BRACKET (for 4WD)
(a) Remove the 3 bolts and bracket.
50. REMOVE TRANSFER ASSEMBLY (for 4WD)
51. REMOVE STARTER ASSEMBLY
52. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
(a) Remove the automatic transaxle for U241E (2WD).
(b) Remove the automatic transaxle for U140F (4WD).
53. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY
(a) Remove the torque converter clutch for U241E (2WD).
(b) Remove the torque converter clutch for U140F (4WD).

Pic 36

54. REMOVE DRIVE PLATE SUB-ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021

pic 37

(b) Remove the 8 bolts, rear spacer, drive plate and front spacer.

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Install

INSTALLATION
1. INSTALL DRIVE PLATE SUB-ASSEMBLY
(a) Clean the 8 bolts and 8 bolt holes.
(b) Apply adhesive to 2 or 3 threads of the 8 bolts.
Adhesive: Toyota Genuine Adhesive 1342, Three Bond 1342 or equivalent

pic 38

(c) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021

pic 39

(d) Install the front spacer.

HINT: Align the pin of the front spacer with the pin hole of the crankshaft.

Pic 40

(e) Install the drive plate and rear spacer onto the crankshaft.

Pic 41

(f) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 98 Nm (1,000 kgf-cm, 72 ft. Lbs.)
2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY
(a) Install the torque converter clutch for U241E (2WD).
(b) Install the torque converter clutch for U140F (4WD).
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) Install the automatic transaxle for U241E (2WD).
(b) Install the automatic transaxle for U140F (4WD).
4. INSTALL STARTER ASSEMBLY
5. INSTALL TRANSFER ASSEMBLY (for 4WD)

pic 42

6. INSTALL DRIVE SHAFT BEARING BRACKET (for 2WD)
(a) Install the bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. Lbs.)

pic 43

7. INSTALL DRIVE SHAFT BEARING BRACKET (for 4WD)
(a) Install the bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. Lbs.)

pic 44

8. INSTALL ENGINE HANGER
(a) Install the No. 1 and No. 2 engine hangers.
Torque: 38 Nm (387 kgf-cm, 28 ft. Lbs.)

Part No.
Pic 45

pic 46

(b) Attach the sling device and the engine with the chain block.
9. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Lift the engine assembly (with transaxle) with the chain block.

Pic 47

(b) Lower the engine out of the vehicle slowly and carefully.

NOTICE: Make sure the engine is clear of all wiring, hoses and cables.

Pic 48

10. INSTALL ENGINE MOUNTING INSULATOR LH
(a) Install the engine mounting insulator LH with the 4 bolts.
Torque: 95 Nm (969 kgf-cm, 70 ft. Lbs.)

pic 49

(b) Install the engine mounting insulator LH with the through bolt and nut.

HINT: Install the through bolt by tightening the nut.

Torque: 56 Nm (571 kgf-cm, 41 ft. Lbs.)

pic 50

11. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH with the 2 bolts and 2 nuts.
Torque:
95 Nm (969 kgf-cm, 70 ft. Lbs.) For bolt
95 Nm (969 kgf-cm, 70 ft. Lbs.) For nut A
52 Nm (530 kgf-cm, 38 ft. Lbs.) For nut B

pic 51

12. REMOVE ENGINE HANGER
(a) Remove the No. 1 and No. 2 engine hangers.

Pic 52

13. INSTALL ENGINE MOUNTING INSULATOR RR
(a) Install the engine mounting insulator RR with the 2 nuts and 2 bolts.
Torque: 95 Nm (969 kgf-cm, 70 ft. Lbs.)

pic 53

(b) Install the through bolt which is used to secure the rear engine mounting insulator, into the rear engine mounting bracket.
Torque: 95 Nm (969 kgf-cm, 70 ft. Lbs.)

pic 54

14. INSTALL ENGINE MOUNTING INSULATOR FR
(a) Install the engine mounting insulator FR with the 2 bolts.
Torque: 95 Nm (969 kgf-cm, 70 ft. Lbs.)

pic 55

(b) Install the through bolt and nut which is used to secure the front engine mounting bracket FR.

HINT: Install the through bolt by tightening the nut.

Torque: 145 Nm (1,479 kgf-cm, 107 ft. Lbs.)
15. INSTALL PROPELLER SHAFT ASSEMBLY (for 4WD)
(a) Install the propeller shaft.
16. INSTALL FRONT DRIVE SHAFT ASSEMBLY
(a) Install the front drive shaft RH (for 2WD).
(b) Install the front drive shaft RH (for 4WD).
17. INSTALL FRONT EXHAUST PIPE

pic 56

18. CONNECT ENGINE WIRE
(a) Install the ground cable with the bolt located near the starter.
Torque: 13 Nm (133 kgf-cm, 10 ft. Lbs.)
(b) Connect the ground cable to the clamp located near the starter.

Pic 57

(c) Connect the engine wire to the positive (+) battery terminal with the nut.
Torque: 13 Nm (133 kgf-cm, 10 ft. Lbs.)

pic 58

(d) Connect the ground cable connector.

Pic 59

(e) Connect the 2 engine wire connectors and install the nut.
(f) Install the engine room relay block cover.

Pic 60

(g) Attach the clamp of the engine wire cover.
(h) Install the engine wire cover to with the bolt.
19. INSTALL ECM
20. INSTALL COOLER COMPRESSOR ASSEMBLY
21. INSTALL GENERATOR ASSEMBLY
22. INSTALL FAN AND GENERATOR V BELT
23. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
24. INSTALL TRANSAXLE CONTROL CABLE ASSEMBLY
(a) Install the transaxle control cable for U241E.
(b) Install the transaxle control cable for U140F.
25. INSTALL INTAKE MANIFOLD INSULATOR
26. INSTALL INTAKE MANIFOLD
27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
28. CONNECT NO. 2 VENTILATION HOSE
29. INSTALL THROTTLE BODY ASSEMBLY
30. CONNECT FUEL TUBE

pic 61

31. CONNECT HEATER WATER OUTLET HOSE
(a) Connect the heater water outlet hose to the air conditioner tube.

Pic 62

32. CONNECT HEATER WATER INLET HOSE
(a) Connect the heater water inlet hose to the air conditioner tube.

Pic 63

33. CONNECT UNION TO CONNECTOR TUBE HOSE
(a) Connect the 2 union to connector tube hoses to the booster vacuum tube.

Pic 64

34. INSTALL BATTERY CARRIER BRACKET
(a) Install the battery carrier bracket with the nut and 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. Lbs.)

pic 65

35. INSTALL BATTERY BRACKET REINFORCEMENT
(a) Install the battery bracket reinforcement with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. Lbs.)

pic 66

36. INSTALL FRONT BATTERY CARRIER
(a) Install the front battery carrier with the 4 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. Lbs.)
(b) Connect the 2 clamps of the engine wire.
37. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Connect the air cleaner case to the No. 1 air cleaner inlet.

Pic 67

(b) Install the air cleaner case with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
38. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
39. INSTALL AIR CLEANER CAP
40. INSTALL PURGE VSV

pic 68

41. INSTALL RADIATOR RESERVOIR
(a) Install the reservoir with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
42. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator.
43. INSTALL BATTERY TRAY
44. INSTALL BATTERY
(a) Install the battery.
(b) Install the battery clamp with the bolt and nut.
Torque:
8.5 Nm (87 kgf-cm, 75 inch lbs.) For bolt
5.0 Nm (51 kgf-cm, 44 inch lbs.) For nut
45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
46. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add automatic transaxle fluid for U241E (2WD).
(b) Add automatic transaxle fluid for U140F (4WD).
47. INSPECT FOR FUEL LEAK
48. ADD ENGINE COOLANT
49. INSPECT FOR ENGINE COOLANT LEAK
(a) Check for engine coolant leaks.
50. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK
51. ADJUST SHIFT LEVER POSITION
(a) Adjust the shift lever position for U241E (2WD).
(b) Adjust the shift lever position for U140F (4WD).
52. INSTALL NO. 1 ENGINE COVER
53. INSTALL FRONT FENDER APRON RH
54. INSTALL NO. 2 ENGINE UNDER COVER
55. INSTALL NO. 1 ENGINE UNDER COVER
56. INSTALL FRONT WHEEL
57. INSTALL RADIATOR SUPPORT OPENING COVER
58. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood.
(b) Adjust the hood.
59. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment.
60. PERFORM REGISTRATION See: Cruise Control > Programming and Relearning
(a) When replacing the engine assembly, perform vehicle stability control system recognition in ECM.
61. RESET MEMORY (for Automatic Transaxle)
(a) When replacing the engine assembly, perform the RESET MEMORY procedure (A/T initialization) for U241E (2WD) and for U140F (4WD). See: Automatic Transmission/Transaxle > Programming and Relearning > Initialization

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I hope this helps. Let me know if you have other questions.

Take care and God Bless,

Joe