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Transfer Assembly: Disassembly

  1. REMOVE HOSE 
    1. Remove an actuator motor breather hose.
      Fig 1: Identifying Actuator Motor Breather Hose
      G05261739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE SWITCH 
    1. Remove the indicator No. 1 and No. 2 switches, case No. 1 plug and gaskets.
      Fig 2: Identifying Indicator No. 1 & No. 2 Switches
      G05261740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE TRANSFER GEAR SHIFT HEAD NO. 2 
    1. Using a pin punch and hammer, remove the slotted pin from the gear shift head No. 2.
      Fig 3: Identifying Gear Shift Head No. 2 Slotted Pin
      G05261741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY 
    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.

      Fig 4: Identifying Transfer RH Bearing Retainer Sub-Assembly Bolts
      G05261742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSFER COVER TYPE T OIL SEAL 
    1. Using a screwdriver and hammer, remove the oil seal from the bearing retainer sub-assembly.
  6. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Remove the 4 bolts and the case cover sub-assembly.
      Fig 5: Identifying Transfer Case Cover Sub-Assembly Bolts
      G04963812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE BREATHER OIL DEFLECTOR 
  8. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    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 

      Fig 6: Using SST To Hold Output Shaft Companion Flange & Remove Output Shaft Companion Flange Lock Nut
      G04963813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

      Fig 7: Using SST To Remove Output Shaft Companion Flange Sub-Assembly (Front)
      G04963814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. 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).
  10. 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) 

  11. 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).
  12. REMOVE EXTENSION HOUSING SUB-ASSEMBLY 
    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.

      Fig 8: Identifying Extension Housing Sub-Assembly Bolts
      G04963815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using a screwdriver and hammer, remove the extension housing type T oil seal.
  14. REMOVE TRANSFER OUTPUT WASHER 
    1. Remove the 2 output washers and collar.
      Fig 9: Identifying Transfer Output Washers & Collar
      G05261747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSFER REAR CASE 
    1. Remove the 12 bolts and 2 clamps.
      Fig 10: Identifying Transfer Rear Case Bolts & Clamps
      G04963817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the transfer rear case.

      HINT:

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

  16. 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.
      Fig 11: Identifying Spring & Ball
      G05261749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  17. REMOVE CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE 
    1. Using 2 screwdrivers and a hammer, tap out the shift fork shaft snap ring.
      Fig 12: Using Screwdrivers & Hammer To Tap Out Shift Fork Shaft Snap Ring
      G04963821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, CTR differential lock fork sub-assembly and front drive clutch sleeve.
      Fig 13: Identifying CTR Differential Lock Fork Sub-Assembly & Front Drive Clutch Sleeve Bolt
      G05261751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE REAR OUTPUT SHAFT SUB-ASSEMBLY 
    1. Using a snap ring expander, remove the output shaft snap ring.
      Fig 14: Using Snap Ring Expander To Remove Output Shaft Snap Ring
      G05261752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      Fig 15: Identifying Rear Output Shaft Sub-Assembly
      G05261753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the rear output shaft sub-assembly front drive chain and driven sprocket sub-assembly.
      Fig 16: Identifying Rear Output Shaft Sub-Assembly Front Drive Chain & Driven Sprocket Sub-Assembly
      G04963825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    1. Using a press, remove the driven sprocket bearing.
      Fig 17: Using Press To Remove Transfer Driven Sprocket Bearing
      G04963827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING 
    1. Using SST, a press and steel bar, remove the transfer input gear radial ball bearing.

      SST 09555-55010 

      Fig 18: Using SST, Press & Steel Bar To Remove Transfer Input Gear Radial Ball Bearing
      G04963828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.
      Fig 19: Using Screwdrivers & Hammer To Tap Out Snap Ring
      G04963829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and transfer shift actuator assembly.
      Fig 20: Identifying Transfer Shift Actuator Assembly Bolts
      G04963830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE TRANSFER CASE NO. 1 PLUG 
    1. Remove the transfer case No. 1 plug (filler plug) and gasket.
  23. REMOVE TRANSFER CASE NO. 1 PLUG 
    1. Remove the transfer case No. 1 plug (drain plug) and gasket.
  24. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Remove the 3 bolts and oil separator sub-assembly.
      Fig 21: Identifying Transfer Oil Separator Sub-Assembly Bolts
      G05261759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSFER CASE MAGNET 
  26. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Remove the 3 bolts and oil pump body sub-assembly.
      Fig 22: Identifying Transfer Oil Pump Body Sub-Assembly Bolts
      G05261760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE TRANSFER OIL PUMP BODY O-RING 
    1. Using a screwdriver, remove the oil pump body CD-ring.
      Fig 23: Using Screwdriver To Remove Oil Pump Body CD-Ring
      G04963833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE TRANSFER OIL PUMP GEAR 
    1. Remove the transfer oil pump gear.
      Fig 24: Identifying Transfer Oil Pump Gear
      G04963834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY 
    1. Using a snap ring expander, remove the snap ring.
      Fig 25: Using Snap Ring Expander To Remove Snap Ring
      G04963835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the low planetary gear assembly and input shaft sub-assembly.
      Fig 26: Identifying Low Planetary Gear Assembly & Input Shaft Sub-Assembly
      G04963836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE TRANSFER OUTPUT SHAFT SPACER 
  31. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
  32. 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).
  33. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    1. Using a snap ring expander, remove the input gear stopper shaft snap ring.
      Fig 27: Using Snap Ring Expander To Remove Input Gear Stopper Shaft Snap Ring
      G04963838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TRANSFER INPUT GEAR STOPPER 
  35. REMOVE TRANSFER INPUT GEAR STOPPER BALL 
  36. REMOVE MANUAL TRANSFER PLANETARY CARR WASHER 
  37. REMOVE TRANSFER INPUT SHAFT 
  38. REMOVE NO. 1 TRANSFER THRUST BEARING RACE 
  39. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
  40. REMOVE TRANSFER NO. 1 INPUT SHAFT SEAL RING 
  41. INSPECT TRANSFER INPUT SHAFT 
    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.

      Fig 28: Measuring Outer Diameter Of Input Shaft Journal Surface Using Micrometer
      G04963842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator, measure the inside diameter of the input shaft bushing.

      Minimum diameter: 

      48.14 mm (1.8953 in.) 

      Fig 29: Measuring Inside Diameter Of Input Shaft Bushing Using Dial Indicator
      G04963843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE 
    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.

      Fig 30: Measuring Thrust Clearance Of Planetary Pinion Gear Using Feeler Gauge
      G04963844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE 
    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.

      Fig 31: Measuring Radial Clearance Of Planetary Pinion Gear Using Dial Indicator
      G04963845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. 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 

      Fig 32: Using SST & Press To Remove Transfer Input Shaft Bearing
      G04963991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, remove the snap ring.
      Fig 33: Using Screwdriver To Remove Snap Ring
      G04963847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the low planetary gear spline piece.
  46. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    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.
      Fig 34: Using SST To Remove Low Planetary Gear Bearing
      G04963848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSPECT DRIVE SPROCKET THRUST CLEARANCE 
    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.

      Fig 35: Measuring Drive Sprocket Thrust Clearance Using Feeler Gauge
      G05261773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSPECT DRIVE SPROCKET RADIAL CLEARANCE 
    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.

      Fig 36: Measuring Radial Clearance Of Drive Sprocket Using Dial Indicator
      G04963850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING 
    1. Using a snap ring expander, remove the snap ring.
      Fig 37: Using Snap Ring Expander To Remove Transfer Low Planetary Ring Gear Hole Snap Ring
      G04963851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE TRANSFER OUTPUT SHAFT SPACER NO. 2 
  51. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL 
  52. REMOVE CENTER DIFFERENTIAL CASE 
  53. REMOVE TRANSFER CLUTCH HUB 
    1. Remove the transfer clutch hub.
      Fig 38: Identifying Transfer Clutch Hub
      G04963852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
  55. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER 
  56. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST and a press, remove the output shaft rear radial ball bearing.

      SST 09555-55010 

      Fig 39: Using SST & Press To Remove Transfer Output Shaft Rear Radial Ball Bearing
      G04963855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER 
    1. Remove the transfer output shaft spacer.
      Fig 40: Identifying Transfer Output Shaft Spacer
      G04963856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
  59. REMOVE TRANSFER DRIVE SPROCKET BEARING 
  60. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER 
  61. INSPECT REAR OUTPUT SHAFT SUB-ASSEMBLY 
    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.

      Fig 41: Measuring Outer Diameter Of Output Shaft Rear Journal Surface Using Micrometer
      G04963857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO. 2 CLEARANCE 
    1. Using vernier calipers, measure the thickness of the gear shift fork No. 2 claw.

      Thickness: 

      10 mm (0.3937 in.) 

      Fig 42: Measuring Thickness Of Gear Shift Fork No. 2 Claw Using Vernier Calipers
      G04963858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  63. INSPECT FRONT DRIVE CLUTCH SLEEVE AND CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY CLEARANCE 
    1. Using vernier calipers, measure the thickness of the No. 1 gear shift fork claw.

      Thickness: 

      10 mm (0.3937 in.) 

      Fig 43: Measuring Thickness Of No. 1 Gear Shift Fork Claw Using Vernier Calipers
      G04963859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  64. INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE 
    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.
      Fig 44: Identifying Center Differential Case, High & Low Clutch Sleeve
      G04963860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE 
    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.
      Fig 45: Identifying Center Differential Case & Front Drive Clutch Sleeve
      G04963861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. REMOVE TRANSFER CASE PLUG 
    1. Remove the transfer case plug.
      Fig 46: Identifying Transfer Case Plug
      G04963862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE COMPRESSION SPRING 
  68. REMOVE HEAD PIN 
  69. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    1. Using a screwdriver, remove the snap ring.
      Fig 47: Using Screwdriver To Remove Snap Ring
      G04963863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the low planetary ring gear from the front case.
      Fig 48: Identifying Low Planetary Ring Gear Position
      G04963864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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