Because there is an AutoX tomorrow, my distributor started gushing oil yesterday. After removing the cap and getting the thing out, which was so easy I should have seen this coming, the rotor is completely stuck.
The repair guide is quite humorous. In one pic it's on, and in the next pic titled "if necessary, remove the rotor" ABRA CADABRA, it's off.
http://www.autozone.com/addVehicleId,1618201/initialAction,repairGuide/shopping/repairGuide.htm?pageId=0900c1528006efab
Anyone know how to remove this thing? From the diagram it seems to use some sort of clip mechanism, but if it wasn't made of plastic I'd swear it was welded on. 
edit for late night + early morning exhaustion
I've been looking around and it seems that a fused-on rotor is a common problem, and the only suggestion I've seen so far is to shatter it off.
They usually leak at an internal oil seal. If the 4AF dizzy is like the 4AG dizzy, there should be a pin you'll have to drive out to get the gear off. Look around the web for a how-to-fix your 4AGE distributor. Probably on club4ag.com or MR2OC.com. The seal itself is cheap, but Toyota considers the whole thing as not serviceable and just sells you a new dizzy.
Well I shattered off the rotor and got a new rotor and seals...and just figured out the problem with the pin. Is this pin reusable after being driven out? And do you have any suggestions for driving the pin out with unconventional tools?
OK now the ignition coil is stuck to the distributor housing :( I think it was RTV'd on.
It was stuck on with some sort of sealant...I got it pried off. Should be smooth sailing from here. <--jinxes self again
A tip broke off of the signal rotor...that's that for entertainment until September :( :( :(
OK I soldered a new tip onto the signal rotor...any tips for driving the pin out?
I tried a jeweller's-style allen key scredriver and a small wooden mallet...it doesn't budge.
I've never had to do that seal myself, so I can't give you any "here's how I did it" experience. I've seen the pin and seen right ups on it. Search around the sites for a how-to. Usually a drift and a 3 lb maul will take care of most pins.
I used a punch and hammer to get the old pin out. I didn't take any chances on reusing it, a new one is so cheap it didn't seem worth it.
Here's where I got my kit for the 4A-G and I can't recommend it enough, it worked really well...the link is straight to the 4A-F kit:
http://www.kbox.ca/catalog/product_info.php?cPath=43&products_id=262
Hey I'm having the same problem. I really didn't think it would be sooo difficult to replace that inner seal. With regards to the shaft removal, is there another way to get to the inner seal without removing the shaft pin ?
What is the purpose of the phillips screw that goes into the Signal Rotor Shaft in the diagram ?
It appears as though the entire shaft can be separated into two parts ??? [ Just Wondering
]
