Tacoma transfer case removal - Tacoma Toyota Cars & Trucks

look for a c clip at back of transfer case. some have shaft from transmission pass through transfer case.

Remove the transmission & check the clutch & pressure plate.

check that the 4x4 actuator in the transfer case is engaging
( vacuum lines or electrical solenoid)
check that the auto engage for the front wheels is engaging

Check fuse for transfer case. Check electrical connector to transfer case. Listen for transfer case motor running when switch is activated.

On the early Tacoma, the speed sensor is located in the cluster and is driven by a cable attached to the transmission.
Later models moved the sensor to the transmission tailshaft or transfer case and eliminated the cable.
If you do not have a speedometer cable, your sensor is on the transmission.

There are actually two actuators, one is located in the transfer case and one on the front differential. the one on the transfer case provides power to both front and rear driveshafts, the front actuator must engage so that the front differential locks and provide traction to the front wheels. This means that even if the transfer case is engaged in 4x4 mode the front wheels will not have traction if the front diff actuator is not working.

More often than not, inactivity is the number one cause for your issues, and this is a common issue.

What we do here, when this situation is presented to us, is to raise the vehicle up on a vehicle hoist, put the vehicle in 4WD, and we tap on the back side of the transfer case with a large rubber mallet. The tapping action frees off the internal motor, which is usually seized. This is not a critical failure, it is just 'stuck'. Tapping on the transfer case usually unsticks the transfer motor.

Note: Please do NOT attempt this without a vehicle hoist. Using jackstands, aor any other means of raising the vehicle can and will be DANGEROUS to the person tapping on the transfer case.

Its a lot heavier to deal with if you leave the transfer box in place. Saying that its one less job to do when you put it back. Either way your probably going to need help if you don't have a hoist.

First be sure transmission is in neutral , let off brake to be sure vehicle will not roll , engage 4 wheel and it will lock up .....