T-SB-0149-10 June 10, 2010

Clicking Noise from Transfer Case

Service
Category Drivetrain

Section Transfer/4wd/Awd Market USA

Applicability

YEAR(S) MODEL(S) ADDITIONAL INFORMATION

2010 Tacoma Drive Type(s): 4WD

VDS(s): LU4EN, MU4FN, PX4EN, UU4EN,
UX4EN

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.

Production Change Information

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

* 11th digit in VIN indicates production plant: M = TMMBC, Z = NUMMI.

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.

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Clicking Noise from Transfer Case

Repair Procedure Overview

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

OP CODE DESCRIPTION TIME OFP T1 T2

TC1006 R & R Transfer Case Needle Bearing 7.8 90364-37013 91 51

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.

Warranty application is limited to occurrence of the specified condition described in this

bulletin.

Parts Information

PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY

90364-37013 Same Bearing, Needle Roller 1

90311-41013 Same 1
Seal, Type T, Oil
90311-41007 Same 1
90312-23001 Same Seal, Type V, Oil 2
90179-22016 Same Lock Nut, Companion Flange* 2

* Non-reusable.

Required Tools & Equipment

REQUIRED MATERIAL QUANTITY

FIPG Sealant: Three Bond 1281, or equivalent As Needed

Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344,
As Needed
Loctite 242, or Equivalent
Hypoid Gear Oil API GL-4 or GL-5, SAE 75W-90 As Needed
MP (Multi-Purpose) Grease As Needed

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Clicking Noise from Transfer Case

Required Tools & Equipment (Continued)

REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY

JSPSM06606
ChassisEAR (or equivalent) ADE 1
(JS Products)

NOTE
A mechanics stethoscope or similar tool may be used in place of ChassisEAR.

ChassisEAR may be ordered by calling Approved Dealer Equipment (ADE) at 1-800-368-6787.

SPECIAL SERVICE TOOLS (SST) PART NUMBER QTY

Companion Flange Holding Tool* 09330-00021 1

Universal Puller Set B* 09950-40011
(Hanger 200, (09951-04020,
Slide Arm, 09952-04010,
Center Bolt 200, 09953-04030,
1
Arm 25, 09954-04010,
Claw No. 5, 09955-04051,
Attachment, 09957-04010,
Holder) 09958-04011)
09555-55010-01
Output Flange Remover 1
(or Equivalent)
09316-60011
Transmission Transfer Bearing Replacer Set
(09316-00011,
(Replacer Pipe, 1
09316-00071)
Replacer F)
(or Equivalent)
09554-22010
Differential Oil Seal Replacer 1
(or Equivalent)
Replacer Set 1* 09950-60010-01
1
(Replacer 32) (09951-00320)
Handle Set* 09950-70010-01
1
(Handle Assembly 100 4.25 inch) (09951-07100-01)
Steering Knuckle Tool* 09649-17010

* Essential SST.

NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Disassembly

1. Test drive the vehicle and confirm the condition.

2. Confirm noise is loudest from the rear output area Figure 1. .
of the transfer case using ChassisEAR or a
technicians stethoscope (or equivalent). (See
Figure 1.)
Is the noise loudest near the rear driveshaft
output area?
YES Go to step 3.
NO This TSB does NOT apply, continue
diagnosis to determine the cause of the
noise.

3. Remove the transfer case.

Refer to the Technical Information System (TIS), 2010 model year Tacoma Repair Manual:
Drivetrain Transfer/4wd/Awd VF2BM Transfer: Transfer Assembly: Removal
4. Remove the front and rear output shaft companion flange sub-assemblies.
A. Using a chisel and hammer, loosen the staked part of the output shaft lock nut.

B. Using the SST to hold the output shaft Figure 2.

companion flange, remove the output shaft
lock nut.
SST: 09330-00021

1 SST

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Disassembly (Continued)

C. Using the SST, remove the output shaft Figure 3.

companion flange sub-assembly (front side).
SST: 09950-40011 (09951-04020, 09952-04010,
09953-04030, 09954-04010, 09955-04051,
09957-04010, 09958-04011)

1 SST

5. Manual Transmission ONLY:

Remove the speedometer driven gear sub-assembly.
Remove the bolt and speedometer driven gear with sensor.
6. Remove the transfer case extension housing Figure 4. .
sub-assembly front by removing the 5 bolts.

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.

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Disassembly (Continued)

10. Remove the transfer rear case by removing the Figure 5. .

12 bolts and 2 brackets.

HINT
If necessary, tap the transfer rear case with a
plastic hammer to remove it.

11. Remove both shift detent springs and balls. Figure 6. .

Using a hexagon wrench (6 mm), remove the
2 shift detent ball spring plugs, 2 shift fork
compression springs, and 2 shift detent balls.

12. Remove the 2 snap rings from the shift forks. Figure 7. .

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Disassembly (Continued)

13. Remove the bolt and shift shaft stopper. Figure 8. .

14. Remove the rear output shaft snap ring using a Figure 9. .
snap ring expander.

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Disassembly (Continued)

15. Remove the output shaft assembly, driven Figure 10. .

sprocket assembly, drive chain, shift shaft, and
shift forks No. 1 and No. 2 as an assembly.
A. Mount the transfer rear case in a vise.
B. Using a plastic hammer, carefully tap the
transfer rear case and remove the rear output
shaft assembly, driven sprocket assembly,
front drive chain, shift shaft, and shift forks
No. 1 and No. 2.
C. Remove the driven sprocket assembly, front
drive chain, shift shaft, and shift forks No. 1
and No. 2 from the rear output shaft assembly.

NOTICE
Be careful NOT to lose the 2 interlock pins.

16. Inspect the drive sprocket thrust clearance.

Using a feeler gauge, measure the drive sprocket thrust clearance. Record measurement for
later use.
Standard clearance: 0.10 to 0.25 mm (0.0039 to 0.0098 in.)
Maximum clearance: 0.25 mm (0.0098 in.)
Figure 11.

1 Drive Sprocket Thrust Clearance

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Disassembly (Continued)

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.

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Reassembly

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

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Reassembly (Continued)

2. Inspect the drive sprocket thrust clearance.

Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance: 0.10 to 0.25 mm
(0.0039 to 0.0098 in.)
Maximum clearance: 0.25 mm (0.0098 in.)

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.

1 Drive Sprocket Thrust Clearance

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Reassembly (Continued)

3. Install the rear output shaft assembly, front drive chain, driven sprocket assembly, shift shaft, and
shift forks No. 1 and No. 2.

A. Install the driven sprocket assembly, front drive Figure 16.

chain, shift shaft, and shift forks No. 1 and
No. 2 onto the rear output shaft assembly.
3
NOTICE
Make sure that the shift forks No. 1 and
No. 2 are installed facing in the correct
1
direction. 2

HINT
Install shift interlock pins in shift forks No. 1
and No. 2, then slide the shift shaft in place.

1 Shift Fork No. 1

2 Shift Fork No. 2
3 Front

B. Mount the transfer rear case in a vise. Figure 17.

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).

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Reassembly (Continued)

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. .

6. Install the 2 shift shaft snap rings. Figure 20. .

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Reassembly (Continued)

7. Install the shift detent balls and springs. Figure 21. .

A. Install the 2 shift detent balls and 2
compression springs onto the shift forks No.
1 and No. 2.
B. Apply sealant to the shift detent ball spring
plug threads.
Sealant: Three Bond 1344, Loctite 242, or
equivalent

C. Using a hexagon wrench (6 mm), install the

2 shift detent ball spring plugs onto the shift
forks No. 1 and No. 2.
Torque: 18.6 N*m (190 kgf*cm, 14 ft*lbf)

8. Install the transfer extension housing type T oil Figure 22. .

seal.
A. Using the SST and a hammer, tap in a new
extension housing type T oil seal until its
surface is flush with the housing upper surface.
SST: 09554-22010 1

B. Coat the lip of the oil seal with MP grease.

1 SST

9. Install the transfer case oil seal. Figure 23. .

A. Coat the lip of a new oil seal with MP grease.
B. Using the SST and a hammer, tap in the oil
seal until its metal ring contacts the case.
SST: 09649-17010
09950-70010-01 (09951-07100-01)

1 SST

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Reassembly (Continued)

10. Install the transfer rear case.

A. Apply FIPG to the transfer rear case, as shown Figure 24.

in Figure 24.
FIPG: Three Bond 1281, or equivalent
1
NOTE
Be sure to thoroughly clean and dry the
transfer front and rear sealing surfaces
prior to applying FIPG.

1 FIPG

B. Engage the 2 brackets and install the transfer Figure 25.

rear case with the 12 bolts.
Torque: 28 N*m (286 kgf*cm, 21 ft*lbf)

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Reassembly (Continued)

11. Install the transfer extension housing sub-assembly front.

A. Apply FIPG to the extension housing Figure 26.

sub-assembly, as shown in Figure 26.
FIPG: Three Bond 1281, or equivalent 1

NOTE
Be sure to thoroughly clean and dry the
extension housing and transfer case
sealing surfaces prior to applying FIPG.

1 FIPG

B. Apply sealant to the bolt threads.

Sealant: Three Bond 1344,
Loctite 242, or equivalent

C. Install the extension housing sub-assembly Figure 27.

with the 5 bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft*lbf)

12. Manual Transmission ONLY:

Install the speedometer driven gear w/ sensor with the bolt.
Torque: 11.5 N*m (117 kgf*cm, 8 ft*lbf)

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Reassembly (Continued)

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)

C. Using a chisel and hammer, stake the

companion flange lock nut.
3

1 Front
2 Rear
3 SST

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Clicking Noise from Transfer Case

Repair Procedure: Transfer Case Reassembly (Continued)

15. Install the transfer case in the vehicle.

Refer to TIS, 2010 model year Tacoma Repair Manual:
Drivetrain Transfer/4wd/Awd VF2BM Transfer: Transfer Assembly: Installation
16. Test drive the vehicle and confirm proper operation.

2010 Toyota Motor Sales, USA