Transfer Assembly: Disassembly

WARNING: This page is about a different car, the 2007 Lexus GX 470. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE HOSE

Fig 1: Identifying Actuator Motor Breather Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove an actuator motor breather hose.
REMOVE SWITCH

Fig 2: Identifying Indicator No. 1 & No. 2 Switches
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the indicator No. 1 and No. 2 switches, case No. 1 plug and gaskets.
REMOVE TRANSFER GEAR SHIFT HEAD NO. 2

Fig 3: Identifying Gear Shift Head No. 2 Slotted Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a pin punch and hammer, remove the slotted pin from the gear shift head No. 2.
REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY

Fig 4: Identifying Transfer RH Bearing Retainer Sub-Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 5 bolts and the bearing retainer sub-assembly.
  HINT:
  
  If necessary, tap the extension housing with a plastic hammer to remove it.
REMOVE TRANSFER COVER TYPE T OIL SEAL
1. Using a screwdriver and hammer, remove the oil seal from the bearing retainer sub-assembly.
REMOVE TRANSFER CASE COVER SUB-ASSEMBLY

Fig 5: Identifying Transfer Case Cover Sub-Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 4 bolts and the case cover sub-assembly.
REMOVE BREATHER OIL DEFLECTOR
REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

Fig 6: Using SST To Hold Output Shaft Companion Flange & Remove Output Shaft Companion Flange Lock Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut (front).
2. Using SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut (front).
  SST 09330-00021
3. Using SST, remove the output shaft companion flange sub-assembly (front).
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
1. Using a screwdriver and hammer, remove the companion flange oil seal from the output shaft companion flange sub-assembly (front).
REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Remove the rear output shaft companion flange sub-assembly using the same procedure as for the front output shaft companion flange sub-assembly (rear).
  SST 09330-00021, 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
1. Using a screwdriver and hammer, remove the companion flange oil seal from the output shaft companion flange sub-assembly (rear).
REMOVE EXTENSION HOUSING SUB-ASSEMBLY

Fig 8: Identifying Extension Housing Sub-Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 5 bolts and extension housing assembly.
  HINT:
  
  If necessary, tap the extension housing assembly rear with a plastic hammer to remove it.
REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
1. Using a screwdriver and hammer, remove the extension housing type T oil seal.
REMOVE TRANSFER OUTPUT WASHER

Fig 9: Identifying Transfer Output Washers & Collar
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 output washers and collar.
REMOVE TRANSFER REAR CASE

Fig 10: Identifying Transfer Rear Case Bolts & Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 12 bolts and 2 clamps.
2. Remove the transfer rear case.
  HINT:
  
  If necessary, tap the transfer rear case with a plastic hammer to remove it.
REMOVE NO. 2 TRANSFER GEAR SHIFT FORK WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE
1. Using a hexagon wrench, remove the plug No. 1.
2. Using a magnetic finger, remove the spring and ball from the hole.
3. Using a pin punch and hammer, drive out the slotted spring pin.
4. Remove gear shift fork No. 2 and high and low shift fork shaft.
5. Remove the high and low clutch sleeve.
REMOVE CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE

Fig 12: Using Screwdrivers & Hammer To Tap Out Shift Fork Shaft Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using 2 screwdrivers and a hammer, tap out the shift fork shaft snap ring.
2. Remove the bolt, CTR differential lock fork sub-assembly and front drive clutch sleeve.
REMOVE REAR OUTPUT SHAFT SUB-ASSEMBLY

Fig 14: Using Snap Ring Expander To Remove Output Shaft Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a snap ring expander, remove the output shaft snap ring.
2. Mount the transfer case rear in a vise.
3. Using a plastic hammer, carefully tap the transfer case rear and remove the rear output shaft sub-assembly together with front drive chain and driven sprocket sub-assembly.
4. Remove the rear output shaft sub-assembly front drive chain and driven sprocket sub-assembly.
REMOVE TRANSFER DRIVEN SPROCKET BEARING

Fig 17: Using Press To Remove Transfer Driven Sprocket Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a press, remove the driven sprocket bearing.
REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING

Fig 18: Using SST, Press & Steel Bar To Remove Transfer Input Gear Radial Ball Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST, a press and steel bar, remove the transfer input gear radial ball bearing.
  SST 09555-55010
REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY

Fig 19: Using Screwdrivers & Hammer To Tap Out Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
2. Remove the 3 bolts and transfer shift actuator assembly.
REMOVE TRANSFER CASE NO. 1 PLUG
1. Remove the transfer case No. 1 plug (filler plug) and gasket.
REMOVE TRANSFER CASE NO. 1 PLUG
1. Remove the transfer case No. 1 plug (drain plug) and gasket.
REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY

Fig 21: Identifying Transfer Oil Separator Sub-Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 3 bolts and oil separator sub-assembly.
REMOVE TRANSFER CASE MAGNET
REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY

Fig 22: Identifying Transfer Oil Pump Body Sub-Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 3 bolts and oil pump body sub-assembly.
REMOVE TRANSFER OIL PUMP BODY O-RING

Fig 23: Using Screwdriver To Remove Oil Pump Body CD-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, remove the oil pump body CD-ring.
REMOVE TRANSFER OIL PUMP GEAR

Fig 24: Identifying Transfer Oil Pump Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the transfer oil pump gear.
REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY

Fig 25: Using Snap Ring Expander To Remove Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a snap ring expander, remove the snap ring.
2. Remove the low planetary gear assembly and input shaft sub-assembly.
REMOVE TRANSFER OUTPUT SHAFT SPACER
REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
REMOVE TRANSFER CASE OIL SEAL
1. Using a screwdriver and hammer, remove the transfer case oil seal (No. 1).
2. Using a screwdriver and hammer, remove the transfer case oil seal (No. 2).
REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING

Fig 27: Using Snap Ring Expander To Remove Input Gear Stopper Shaft Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a snap ring expander, remove the input gear stopper shaft snap ring.
REMOVE TRANSFER INPUT GEAR STOPPER
REMOVE TRANSFER INPUT GEAR STOPPER BALL
REMOVE MANUAL TRANSFER PLANETARY CARR WASHER
REMOVE TRANSFER INPUT SHAFT
REMOVE NO. 1 TRANSFER THRUST BEARING RACE
REMOVE TRANSFER LOW PLANETARY GEAR BEARING
REMOVE TRANSFER NO. 1 INPUT SHAFT SEAL RING
INSPECT TRANSFER INPUT SHAFT

Fig 28: Measuring Outer Diameter Of Input Shaft Journal Surface Using Micrometer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a micrometer, measure the outer diameter of the input shaft journal surface.
  Minimum diameter:
  
  47.59 mm (18736 in.)
  
  If the outer diameter is less than the minimum, replace the input shaft.
2. Using a dial indicator, measure the inside diameter of the input shaft bushing.
  Minimum diameter:
  
  48.14 mm (1.8953 in.)
INSPECT PLANETARY PINION GEAR THRUST CLEARANCE

Fig 30: Measuring Thrust Clearance Of Planetary Pinion Gear Using Feeler Gauge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a feeler gauge, measure the thrust clearance of the planetary pinion gear.
  Standard clearance:
  
  0.11 to 0.84 mm (0.0043 to 0.0331 in.)
  
  Maximum clearance:
  
  0.84 mm (0.0331 in.)
  
  If the clearance exceeds the maximum, replace the planetary gear assembly.
INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE

Fig 31: Measuring Radial Clearance Of Planetary Pinion Gear Using Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a dial indicator, measure the radial clearance of the planetary pinion gear.
  Standard clearance:
  
  0.009 to 0.038 mm (0.0004 to 0.0015 in.)
  
  Maximum clearance:
  
  0.038 mm (0.0015 in.)
  
  If the clearance exceeds the maximum, replace the planetary gear assembly.
REMOVE TRANSFER INPUT SHAFT BEARING
1. Using a snap ring expander, remove the input bearing shaft snap ring.
2. Using SST and a press, remove the input shaft bearing.
  SST 09554-30011,09555-55010
REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE

Fig 33: Using Screwdriver To Remove Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, remove the snap ring.
2. Remove the low planetary gear spline piece.
REMOVE TRANSFER LOW PLANETARY GEAR BEARING

Fig 34: Using SST To Remove Low Planetary Gear Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST, remove the low planetary gear bearing.
  SST 09612-65014 (09612-01030, 09612-01050)
  
  NOTE: Hang SST securely to the clearance between the bearing and the low planetary gear.
INSPECT DRIVE SPROCKET THRUST CLEARANCE

Fig 35: Measuring Drive Sprocket Thrust Clearance Using Feeler Gauge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a feeler gauge, measure the drive sprocket thrust clearance.
  Standard clearance:
  
  0.15 to 0.24 mm (0.0059 to 0.0094 in.)
  
  Maximum clearance:
  
  0.24 mm (0.0094 in.)
  
  If the clearance exceeds the maximum, replace the drive sprocket.
INSPECT DRIVE SPROCKET RADIAL CLEARANCE

Fig 36: Measuring Radial Clearance Of Drive Sprocket Using Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a dial indicator, measure the radial clearance of the drive sprocket.
  Standard clearance:
  
  0.01 to 0.06 mm (0.0004 to 0.0024 in.)
  
  Maximum clearance:
  
  0.06 mm (0.0024 in.)
  
  If the clearance exceeds the maximum, replace the drive sprocket, output shaft rear or needle roller bearing.
REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING

Fig 37: Using Snap Ring Expander To Remove Transfer Low Planetary Ring Gear Hole Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a snap ring expander, remove the snap ring.
REMOVE TRANSFER OUTPUT SHAFT SPACER NO. 2
REMOVE TRANSFER OUTPUT SHAFT SPACER BALL
REMOVE CENTER DIFFERENTIAL CASE
REMOVE TRANSFER CLUTCH HUB

Fig 38: Identifying Transfer Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the transfer clutch hub.
REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER
REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING

Fig 39: Identifying Transfer Output Shaft Rear Radial Ball Bearing Using SST & Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, remove the output shaft rear radial ball bearing.
  SST 09555-55010
REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER

Fig 40: Identifying Transfer Output Shaft Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the transfer output shaft spacer.
REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
REMOVE TRANSFER DRIVE SPROCKET BEARING
REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER
INSPECT REAR OUTPUT SHAFT SUB-ASSEMBLY

Fig 41: Measuring Outer Diameter Of Output Shaft Rear Journal Surface Using Micrometer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a micrometer, measure the outer diameter of the output shaft rear journal surface.
  Standard diameter:
  
  Part A:
  
  27.98 to 27.99 mm (1.1016 to 1.1020 in.)
  
  Part B:
  
  31.98 to 32.00 mm (1.2591 to 1.2598 in.)
  
  Part C:
  
  34.98 to 35.00 mm (1.3772 to 1.3780 in.)
  
  Part D:
  
  36.98 to 37.00 mm (1.4559 to 1.4567 in.)
  
  Minimum diameter:
  
  Part A:
  
  27.98 mm (1.1016 in.)
  
  Part B:
  
  31.98 mm (1.2591 in.)
  
  Part C:
  
  34.98 mm (1.3772 in.)
  
  Part D:
  
  36.98 mm (1.4559 in.)
  
  If the outer diameter is less than the minimum, replace the output shaft rear.
INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO. 2 CLEARANCE

Fig 42: Measuring Thickness Of Gear Shift Fork No. 2 Claw Using Vernier Calipers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using vernier calipers, measure the thickness of the gear shift fork No. 2 claw.
  Thickness:
  
  10 mm (0.3937 in.)
2. Using vernier calipers, measure the groove of the high and low clutch sleeve.
  Distance:
  
  10.5 mm (0.4134 in.)
3. Calculate a clearance between the high and low clutch sleeve and gear shift fork No. 2 clearance.
  Standard clearance:
  
  0.26 to 0.84 mm (0.0102 to 0.0331 in)
  
  Maximum clearance:
  
  0.84 mm (0.0331 in.)
  
  If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift fork No. 2.
INSPECT FRONT DRIVE CLUTCH SLEEVE AND CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY CLEARANCE

Fig 43: Measuring Thickness Of No. 1 Gear Shift Fork Claw Using Vernier Calipers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using vernier calipers, measure the thickness of the No. 1 gear shift fork claw.
  Thickness:
  
  10 mm (0.3937 in.)
2. Using vernier calipers, measure the groove of the front drive clutch sleeve.
  Distance:
  
  10.5 mm (0.4134 in.)
3. Calculate a clearance between the front drive clutch sleeve and No. 1 gear shift fork.
  Standard clearance:
  
  0.26 to 0.84 mm (0.0102 to 0.0331 in.)
  
  Maximum clearance:
  
  0.84 mm (0.0331 in.)
  
  If the clearance exceeds the maximum, replace the front drive clutch sleeve or No.1 gear shift fork.
INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE

Fig 44: Identifying Center Differential Case, High & Low Clutch Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Check that the tip of the spline gear of the front drive clutch sleeve is not worn.
2. Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly.
INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE

Fig 45: Identifying Center Differential Case And Front Drive Clutch Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Check that the tip of the spline gear of the front drive clutch sleeve is not worn.
2. Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly.
REMOVE TRANSFER CASE PLUG

Fig 46: Identifying Transfer Case Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the transfer case plug.
REMOVE COMPRESSION SPRING
REMOVE HEAD PIN
REMOVE TRANSFER LOW PLANETARY RING GEAR

Fig 47: Using Screwdriver To Remove Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, remove the snap ring.
2. Remove the low planetary ring gear from the front case.