Question about 1991 Toyota Pickup

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Clutch replacement 91 pickup 4x4 toyota

Do we take off transfer case first or take transmission off with it on

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well depends how strong you are, and if you are using a car lift or doing on your back. either way drain the transfer case fluid, should be bolt on bottom, otherwise when you seperate the transfer case from trans there will big mess. take transfer case off first note how it is mounted with paint marker and then take trans out. much easier then leaving together.

Posted on Jan 29, 2009

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Posted on Jan 02, 2017

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99 ford f150 4wd won't engage, clicks but does not engage


Without knowing how the 4X4 works you don't have much chance of finding the problem , (tapping on stuff ) ? There is an electronic control module that makes this system work . Could have DTC'S - diagnostic trouble code's stored in the (GEM)
Transfer Case -Electronic Shift on the Fly (ESOF) Operation The electronic shift on the fly (ESOF) system is an electronic shift 4x4 system that allows the operator to choose between two different 4x4 modes as well as 2-wheel drive. The operator can switch between 2WD and 4H mode at speeds up to 88 km/h (55 mph). To engage or disengage 4L range, the vehicle speed must be less than 5 km/h (3 mph), the brake pedal depressed, and the transmission must be in NEUTRAL.
The transfer case is equipped with an electromagnetic clutch which is located inside the case. This clutch is used to spin up the front driveline when shifting from 2WD to 4H mode at speed. When the control switch on the instrument panel is turned, the generic electronic module (GEM) recognizes that a shift has been requested and activates the electromagnetic clutch and the relays which power the transfer case shift motor. When the shift motor reaches the desired position, as determined by the contact plate position inputs to the GEM, power to the shift relays and motors will be removed. When the transfer case front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the mainshaft hub to the drive sprocket. Finally, the front axle collar is engaged and the electromagnetic clutch is deactivated.
Shifts between 2WD and 4H can be made at any speed up to 88 km/h (55 mph). Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes.
Feature Inputs:
  • 4WD mode switch (various resistances; go to Table 1).
  • Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open; go to Table 4).
Feature Outputs:
  • 4x4 shift motor relay outputs (go to Table 2).
  • Transfer case clutch relay (grounded when relay is activated, open circuit when relay is deactivated).
  • 4x2/4x4 vacuum solenoid (grounded when activated, open circuit when deactivated).
  • Cluster indicators (ground when activated, open circuit when deactivated).
When shifting into or out of 4L, the GEM requires that the vehicle speed be less than 5 km/h (3 mph), the brake is applied, and the transmission is in NEUTRAL.

Feature Inputs:
  • 4WD Mode Switch (various resistances; go to Table 1).
  • Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open; go to Table 4).
  • Output Speed Shaft (OSS) Sensor (Sinusoid Signal: 0.7V-20V, 2.2 Hz/mph).
  • Brake Input (battery voltage when brake is depressed, open circuit when not activated).
  • Transmission Range Sensor (grounded when transmission is in NEUTRAL, open circuit otherwise).
  • Start/Clutch Depressed Input (go to Table 3).
Feature Outputs:
  • 4x4 Shift Motor Relay Outputs (go to Table 2).
  • 4x2/4x4 Vacuum Solenoid (grounded when activated, open circuit when deactivated).
  • Cluster Indicators (grounded when activated, open circuit when deactivated).
  • P1804 Transmission 4-Wheel Drive High Indicator Circuit Failure GEM REFER to Section 413-01A . P1806 Transmission 4-Wheel Drive High Indicator Short Circuit to Battery GEM REFER to Section 413-01A . P1812 Transmission 4-Wheel Drive Mode Select Circuit Failure GEM REFER to the Symptom Chart. P1815 Transmission 4-Wheel Drive Mode Select Short Circuit to Ground GEM REFER to the Symptom Chart. P1820 Transmission Transfer Case Clockwise Shift Relay Coil Circuit Failure GEM GO to Pinpoint Test A . P1822 Transmission Transfer Case Clockwise Shift Relay Coil Short Circuit to Battery GEM GO to Pinpoint Test A . P1824 Transmission 4-Wheel Drive Clutch Relay Circuit Failure GEM GO to Pinpoint Test E . P1826 Transmission 4-Wheel Drive Low Clutch Relay Short Circuit to Battery GEM GO to Pinpoint Test E . P1828 Transmission Transfer Case Counter Clockwise Shift Relay Coil Circuit Failure GEM GO to Pinpoint Test A . P1830 Transmission Transfer Case Counter Clockwise Shift Relay Coil Short Circuit to Battery GEM GO to Pinpoint Test A . P1832 Transmission Transfer Case Differential Lock-Up Solenoid Circuit Failure GEM GO to Pinpoint Test C . P1834 Transmission Transfer Case Differential Lock-Up Solenoid Short Circuit to Battery GEM GO to Pinpoint Test C . P1838 Transmission Transfer Case Shift Motor Circuit Failure GEM REFER to the Symptom Chart. P1846 Transmission Transfer Case Contact Plate 'A' Circuit Failure GEM REFER to the Symptom Chart. P1850 Transmission Transfer Case Contact Plate 'B' Circuit Failure GEM REFER to the Symptom Chart. P1854 Transmission Transfer Case Contact Plate 'C' Circuit Failure GEM REFER to the Symptom Chart. P1858 Transmission Transfer Case Contact Plate 'D' Circuit Failure GEM REFER to the Symptom Chart. P1866 Transmission Transfer Case System Concern - Servicing Required GEM REFER to the Symptom Chart. P1867 Transmission Transfer Case Contact Plate General Circuit Failure GEM REFER to the Symptom Chart. P1876 Transmission Transfer Case 2-Wheel Drive Solenoid Circuit Failure GEM GO to Pinpoint Test C . P1877 Transmission Transfer Case 2-Wheel Drive Solenoid Circuit Short to Battery GEM GO to Pinpoint Test C . P1891 Transmission Transfer Case Contact Plate Ground Return Open Circuit GEM REFER to the Symptom Chart. Your best bet , take it to a qualified repair shop. Tapping on thing's isn't the way to diagnose

Jan 10, 2018 | Cars & Trucks

1 Answer

I have a 93 toy. 4x4 Iam getting ready to change clutch. Can I split the transfer off of the transmission?


it would be to much trouble. it is not that bad to do it with everything together just a little heavier.
have doen at least 40 of these in the last 25 yrs and did not split transfer from trans

Jun 15, 2011 | 1993 Toyota Pickup

1 Answer

What type of fluid or gear oil goes into transfer case 1989 4x4 toyota pickup


Transfer Case Fluid Types

Automatic Trans. Dexron II or III Manual Trans. GL4 or GL5, 75W/90

Feb 23, 2011 | 1989 Toyota Pickup SR5

1 Answer

Do I need to take out the transmission to change the clutch on a 1991 Toyota pickup with 4-wheel drive?


Hello. Welcome to FixYa. I will be happy to assist you.

Yes.

You have to remove the transmission, and the transfer case, from the vehicle to access the clutch assembly. There is no other way to remove the clutch.

Feb 19, 2011 | 1991 Toyota Pickup

1 Answer

I have a clutch out in my pickup. It has 4X4. Do I have to remove the transfer case, and completely remove the transmission to replace the clutch? I believe I think I can do the work myself, but Ive never...


yes you have to remove the transmission all the way becuase you have to align the clutch properly. make sure you send your flywheel out to get resurfaced any local machine shop can do it, it does not cost much to get it resurfaced. if you are doing it on the floor you will want to remove the transfer case( its fairly heavy ) , if you have the luxury of a hoist or even a good floor jack you can pull it off with the transfer care attached, so you can leave it on or take it off its up to you depending on how much room you have to work with

Dec 15, 2010 | 1986 Ford F150 SuperCab

1 Answer

How do you install a clutch on a Pick up Toyota 1994


What engine? four wheel drive?
Remove rear drive shaft, transfer case if it is four wheel drive, and front drive shaft.
Remove transmission.
Get the kit to replace clutch disk, pressure plate and throw out bearing.
If the flywheel is worn, or grooved, replace it or get it turned at a machine shop.

Apr 29, 2010 | 1994 Toyota Pickup

1 Answer

I need instructions on how to put a new clutch in a 1988 toyota 4x4 pick-up.


bit of a job but you can do it remove driveshaft
remove cross bar (most models) disconnect the transfer case disconect the slave cylinder and all the lines going to the cooler support the motor take the trany bolts loose and pull the transmission out
remember that they are heavy ( replace the clutch
use the alinment tool reinstall the new clutch pressure plate and throwout bearing assembly
reinstall the trans /transfer case and drives shafts
crossbar and all the little stuff cooling lines etc
slave cylinder etc good luck

Mar 05, 2010 | Toyota Pickup Cars & Trucks

2 Answers

Transmission


usually japanese and corean cars do fit there transi ...not sure but!

Jul 21, 2009 | 1991 Toyota Pickup

1 Answer

I have a 91 Toyota 4X4 truck. the clutch is hydraulic. Where is the fluid reservoir located?


There is a small "master cylinder", forthe clutch, located on the driver side of the engine compartment, below the master cylinder.

May 06, 2009 | 1991 Toyota Pickup

1 Answer

We are putting a clutch in my 91 toyota pickup 4x4 do we take off the transfer case first or take out the transfer case and transmission together


Hi. Welcome to FixYa. I will do my best to assist you, with the hopes that you will award me with a FixYa rating for my assistance.

What I do, in my service department, is to pull the transmission and the transfer case as on unit. It is faster, and much simpler. There is no reason to pull them separately. That is way too much work.

I hope that this helps you out.

Thanks for choosing FixYa for assistance.

Jan 29, 2009 | 1991 Toyota Pickup

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