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Transfer Assembly: Reassembly

  1. INSTALL TRANSFER LOW PLANETARY RING GEAR 
    1. Install the low planetary ring gear to the front case.
      NOTE: Make sure to install the low planetary ring gear in the correct direction.
      Fig 1: Identifying Transfer Low Planetary Ring Gear Position
      G05261798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring.
      Fig 2: Using Screwdriver To Install Snap Ring
      G04963863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL HEAD PIN 
    1. Install head pin.
  3. INSTALL COMPRESSION SPRING 
  4. INSTALL TRANSFER CASE PLUG 
    1. Apply sealant to the case plug threads.

      Sealant: 

      Part NO. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    2. Install the case plug.

      Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) 

      Fig 3: Identifying Transfer Case Plug
      G04963862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER 
    1. Install the transfer output shaft plate washer.
      Fig 4: Identifying Transfer Output Shaft Plate Washer
      G05261801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL TRANSFER DRIVE SPROCKET BEARING 
  7. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
  8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER 
  9. INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST and a press, install a new output shaft rear radial ball bearing.

      SST 09316-60011 (09316-00011,09316-00071) 

      NOTE: Install the output shaft rear radial ball bearing so that the bearing snap ring groove face to the rear.
      Fig 5: Using SST & Press To Install Transfer Output Shaft Rear Radial Ball Bearing
      G04963879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER 
    1. Install the transfer output shaft plate washer.
      Fig 6: Identifying Transfer Output Shaft Plate Washer
      G04963852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
  12. INSTALL TRANSFER CLUTCH HUB 
  13. INSTALL CENTER DIFFERENTIAL CASE 
    1. Install the center differential case.
  14. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL 
  15. INSTALL TRANSFER OUTPUT SHAFT SPACER NO. 2 
  16. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING 
    1. Using a snap ring expender, install the snap ring.
      Fig 7: Using Snap Ring Expander To Install Transfer Low Planetary Ring Gear Hole Snap Ring
      G04963851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT DRIVE SPROCKET RADIAL CLEARANCE (See  INSPECTION   ) 
  18. INSPECT DRIVE SPROCKET THRUST CLEARANCE (See  INSPECTION   ) 
  19. INSTALL TRANSFER INPUT SHAFT BEARING 
    1. Using SST and a press, install a new bearing with the groove facing forward.

      SST 09223-15020, 09515-30010, 09950-70010 (09951-07100) 

      Fig 8: Using SST & Press To Install New Transfer Input Shaft Bearing
      G04963885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    1. Using SST and a press, tap in a new low planetary gear bearing.

      SST 09950-60010 (09951-00570), 09950-70010 (09951-07100) 

      Press in depth: 

      7.7 to 8.3 mm (0.303 to 0.327 in.) 

      Fig 9: Using SST & Press To Tap In New Transfer Low Planetary Gear Bearing
      G04963887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, install the spline piece with the snap ring.
      Fig 10: Using Screwdriver To Install Spline Piece With Snap Ring
      G04963847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING 
    1. Select a snap ring that allows the minimum axial play.
      THICKNESS TABLE

      Mark Thickness mm (in.)
      1 1.45 to 1.50 (0.0571 to 0.0591)
      2 1.50 to 1.55 (0.0591 to 0.0610)
      3 1.55 to 1.60 (0.0610 to 0.0630)
      4 1.60 to 1.65 (0.0630 to 0.0650)
      5 1.65 to 1.70 (0.0650 to 0.0669)
    2. Using a snap ring expander, install a new snap ring.
      Fig 11: Checking Transfer Input Bearing Shaft Snap Ring
      G04963845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL TRANSFER NO. 1 INPUT SHAFT SEAL RING 
    1. Apply gear oil to the 2 oil seal rings.
    2. Engage securely to eliminate clearance.
      3. Fig 12: Identifying Transfer No. 1 Input Shaft Seal Ring Clearance
      G04963889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    NOTE: Make sure to install the transfer low planetary gear bearing in the correct direction.
    1. Install the transfer low planetary gear bearing.
      Fig 13: Identifying Transfer Low Planetary Gear Bearing
      G04963840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL NO. 1 TRANSFER THRUST BEARING RACE 
  26. INSTALL TRANSFER INPUT SHAFT 
  27. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER 
    1. Install the manual transfer planetary carrier washer.
      Fig 14: Identifying Manual Transfer Planetary Carrier Washer
      G04963839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL TRANSFER INPUT GEAR STOPPER BALL 
  29. INSTALL TRANSFER INPUT GEAR STOPPER 
  30. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    1. Select an input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) axial play.
      THICKNESS TABLE

      Mark Thickness mm (in.)
      A 2.10 to 2.15 (0.0827 to 0.0846)
      B 2.15 to 2.20 (0.0846 to 0.0866)
      C 2.20 to 2.25 (0.0866 to 0.0886)
      D 2.25 to 2.30 (0.0886 to 0.0906)
      E 2.30 to 2.35 (0.0906 to 0.0925)
      F 2.35 to 2.40 (0.0925 to 0.0945)
      G 2.40 to 2.45 (0.0945 to 0.0965)
      H 2.45 to 2.50 (0.0965 to 0.0984)
      J 2.50 to 2.55 (0.0984 to 0.1004)
      K 2.55 to 2.60 (0.1004 to 0.1024)
      L 2.60 to 2.65 (0.1024 to 0.1043)
      M 2.65 to 2.70 (0.1043 to 0.1063)
      N 2.70 to 2.75 (0.1063 to 0.1083)
      P 2.75 to 2.80 (0.1083 to 0.1102)
      Q 2.80 to 2.85 (0.1102 to 0.1122)
      R 2.85 to 2.90 (0.1122 to 0.1142)
      S 2.90 to 2.95 (0.1142 to 0.1161)
      T 2.95 to 3.00 (0.1161 to 0.1181)
      U 3.00 to 3.05 (0.1181 to 0.1201)
      Fig 15: Checking Transfer Input Gear Stopper Shaft Snap Ring
      G04963892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install the new input gear stopper shaft snap ring.
      Fig 16: Using Snap Ring Expander To Install New Input Gear Stopper Shaft Snap Ring
      G04963893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL TRANSFER CASE OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 1).

      SST 09316-60011 (09316-00011) 

      Fig 17: Using SST & Hammer To Install New No. 1 Transfer Case Oil Seal
      G04963894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the lip of the oil seal with MP grease.
    3. Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 2).

      SST 09304-12012 

      Oil seal drive in depth: 

      -0.5 to 0.5 mm (-0.020 to 0.02 in.) 

      Fig 18: Using SST & Hammer To Install New No. 2 Transfer Case Oil Seal
      G05261815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the lip of the oil seal with MP grease.
  32. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY 
    1. Install the low planetary gear assembly with input shaft sub-assembly.

      HINT:

      If necessary, heat the front case to about 50 to 80°C (122 to 176°F).

      Fig 19: Identifying Low Planetary Gear Assembly With Input Shaft Sub-Assembly
      G04963895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install the shaft snap ring.
      Fig 20: Using Snap Ring Expander To Install Shaft Snap Ring
      G04963835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL TRANSFER OIL PUMP GEAR 
    1. Install transfer oil pump gear.
      Fig 21: Identifying Transfer Oil Pump Gear
      G04963834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL TRANSFER OIL PUMP BODY O-RING 
    1. Coat a new O-ring with gear oil and install it to the oil pump body.
      Fig 22: Identifying Transfer Oil Pump Body O-Ring
      G04964038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Install the oil pump body sub-assembly with the 3 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 23: Identifying Transfer Oil Pump Body Sub-Assembly Bolts
      G04963832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL TRANSFER CASE MAGNET 
    1. Install transfer case magnet.
  37. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Install the oil separator sub-assembly with the 3 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 24: Identifying Transfer Oil Separator Sub-Assembly Bolts
      G05261821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL TRANSFER CASE NO. 1 PLUG 
    1. Install the case plug No. 1 (filler plug) and a new gasket.

      Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 

  39. INSTALL TRANSFER CASE NO. 1 PLUG 
    1. Install the case plug (drain plug) and a new gasket.

      Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 

  40. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY 
    1. Install the shift actuator assembly with the 3 bolts.

      Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

      Fig 25: Identifying Transfer Shift Actuator Assembly Bolts
      G04963830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver and hammer, drive in the 2 snap rings.
  41. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING 
    1. Using SST and a press, install a new input gear radial ball bearing.

      SST 09316-60011 (09316-00031) 

      Fig 26: Using SST & Press To Install New Input Gear Radial Ball Bearing
      G04963902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL TRANSFER DRIVEN SPROCKET BEARING 
    1. Using the press, install a new driven sprocket bearing.
      Fig 27: Using Press To Install New Transfer Driven Sprocket Bearing
      G04963903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY 
    1. Install the rear output shaft sub-assembly and drive sprocket to the front drive chain.
    2. Install the rear output shaft sub-assembly front drive chain and driven sprocket sub-assembly to the case rear.
      Fig 28: Identifying Rear Output Shaft Sub-Assembly, Front Drive Chain & Driven Sprocket
      G04963825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Check that the rear output shaft sub-assembly and driven sprocket sub-assembly turn lightly.
        Fig 29: Identifying Rear Output Shaft Sub-Assembly
        G04963824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • If necessary, heat the rear case to about 50 to 80°C (122 to 176°F).
    3. Using a snap ring expander, install the snap ring.
      Fig 30: Using Snap Ring Expander To Install Snap Ring
      G04963823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE 
    1. Install the CTR differential lock fork sub-assembly and front drive clutch sleeve.
    2. Install the bolt.

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

      Fig 31: Identifying CTR Differential Lock Fork Sub-Assembly & Front Drive Clutch Sleeve With Bolt
      G05261828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver and hammer, drive in the snap ring.
      NOTE: Make sure to install the fork and clutch sleeve in the correct direction.
  45. INSTALL TRANSFER GEAR SHIFT FORK NO. 2 WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE 
    1. Install the gear shift fork No. 2 and high and low shift fork shaft and high and low clutch sleeve.
      NOTE: Make sure to install the fork in the correct direction.
      Fig 32: Identifying Transfer Gear Shift Fork No. 2 Bolt
      G05261829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply sealant to the plug No. 1 threads.

      Sealant: 

      Part NO. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    3. Install the spring and ball to the hole.
    4. Install the plug No. 1 to the hole.

      Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) 

    5. Using a pin punch and hammer, install the slotted pin.
  46. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
    1. Install transfer output shaft front needle roller bearing.
      Fig 33: Identifying Transfer Output Shaft Front Needle Roller Bearing
      G05261830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL TRANSFER OUTPUT SHAFT SPACER 
  48. INSTALL TRANSFER REAR CASE 
    1. Apply FIPG to the case rear.

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 34: Applying FIPG On Case Rear
      G04963913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 clamps and case rear with the 12 bolts.

      Torque: 28 N*m (285 kgf*cm, 21 ft.*lbf) 

      Fig 35: Identifying Transfer Rear Case Bolts & Clamps
      G04963817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL COLLAR 
    1. Install collar.
  50. INSTALL TRANSFER OUTPUT WASHER 
    1. Install 2 output washers.
    Fig 36: Identifying Transfer Output Washers & Collar
    G05261833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST and a hammer, drive in a new oil seal until its surface is flush with the housing upper surface.

      SST 09223-46011, 09631-32020 

      Fig 37: Using SST & Hammer To Install New Transfer Extension Housing Type T Oil Seal
      G04963916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the lip of the oil seal with MP grease.
  52. INSTALL EXTENSION HOUSING SUB-ASSEMBLY 
    1. Apply FIPG to the extension housing assembly rear.

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 38: Identifying FIPG On Extension Housing Assembly Rear
      G04963917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply sealant to the bolt threads.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    3. Install the extension housing assembly with the 5 bolts.

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

      Fig 39: Identifying Extension Housing Sub-Assembly Bolts
      G04963815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using SST and a hammer, drive in a new oil seal (front side).

      SST 09950-60010(09951-00320), 09950-70010 (09951-07100) 

      Fig 40: Using SST & Hammer To Install New Transfer Output Shaft Companion Flange Oil Seal
      G04964054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the lip of the oil seal with MP grease.
  54. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Drive in a new oil seal (rear) in the same way as the oil seal (front).

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

    2. Coat the lip of the oil seal with MP grease.
  55. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Install the companion flange sub-assembly (front side) onto the drive sprocket sub-assembly.
    2. Using SST to hold the companion flange, install a new companion flange lock nut.

      SST 09330-00021 

      Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf) 

    3. Using a chisel and hammer, stake the companion flange lock nut.
  56. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using SST, install the companion flange sub-assembly using the same procedure as for the companion flange sub-assembly (rear side).

      Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf) 

      SST 09330-00021 

      Fig 41: Using SST To Install Output Shaft Companion Flange Sub-Assembly
      G04963920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL BREATHER OIL DEFLECTOR 
  58. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Install the case cover sub-assembly with the 4 bolts.

      Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 

      Fig 42: Identifying Transfer Case Cover Sub-Assembly Bolts
      G04963812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL TRANSFER COVER TYPE T OIL SEAL 
    1. Using SST and a hammer, drive in a new oil seal until its surface is flush with the retainer upper surface.
    2. Coat the lip of the oil seal with MP grease.

      SST 09950-60010 (09951-00590), 09950-70010 (09951-07100) 

      Fig 43: Using SST & Hammer To Install New Transfer Cover Type T Oil Seal
      G04963922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY 
    1. Apply FIPG to the front bearing retainer sub-assembly.

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 44: Identifying FIPG On Front Bearing Retainer Sub-Assembly
      G04963923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply sealant to the bolt threads.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    3. Install the front bearing retainer sub-assembly with the 5 bolts.

      Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf) 

      Fig 45: Identifying Front Bearing Retainer Sub-Assembly Bolts
      G04963811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL TRANSFER GEAR SHIFT HEAD NO.2 
    1. Using a pin punch and hammer, install the slotted pin to the gear shift head No. 2.
      Fig 46: Identifying Transfer Gear Shift Head No. 2 Slotted Pin
      G05261843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL SWITCH 
    1. Install a new gasket, the indicator switches and the case No. 1 plug.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

      Fig 47: Identifying Indicator No. 1 & No. 2 Switches
      G05261844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL HOSES 
    1. Install the hose.
      Fig 48: Identifying Actuator Motor Breather Hose
      G05261739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Place the hose that passes between the transfer rear case and the actuator motor.
    • Adjust the clamp position to prevent the excessive bent or expansion/contraction of the hose.
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