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Transfer Assembly: Reassembly: Reassembly

  1. INSTALL CENTER DIFFERENTIAL CLUTCH CONTROL VALVE 
    1. Install the center differential clutch control valve sleeve, transfer direct clutch modulator valve spring, center differential clutch control valve and center differential clutch control valve plug to the transfer upper valve body.
      Fig 1: Identifying Center Differential Clutch Control Valve
      GTY106760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. While pushing on the center differential control valve plug, install the center differential clutch control valve seat on the transfer upper valve body.
      Fig 2: Locating Center Differential Clutch Control Valve Seat
      GTY106759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL TRANSFER SOLENOID MODULATOR VALVE 
    1. Install the low-high shift valve compression spring, transfer solenoid modulator valve and transfer solenoid modulator valve plug to the transfer upper valve body.
      Fig 3: Identifying Low-High Shift Valve Compression Spring, Transfer Solenoid Modulator Valve And Valve Plug
      GTY106904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. While pushing on the transfer solenoid modulator valve plug, install the transfer solenoid modulator valve plug seat on the transfer upper valve body.
      Fig 4: Locating Transfer Solenoid Modulator Valve Plug Seat
      GTY106905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TRANSFER VALVE BODY COVER 
    1. Install the solenoid oil strainer to the transfer valve body cover.
      Fig 5: Exploded View Of Transfer Valve Body Cover
      GTY106758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transfer valve body cover and transfer valve body plate upper to the transfer upper valve body.
    3. Install the 6 bolts.
      Fig 6: Identifying Bolts
      GTY103613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) 

      HINT: 

      Bolt length: 

      • Bolt A: 35 mm (1.38 in.)
      • Bolt B: 20 mm (0.79 in.)
  4. INSTALL TRANSFER CONTROL SOLENOID 
    1. Install the transfer control solenoid and solenoid lock plate to the transfer upper valve body with the bolt.
      Fig 7: Installing Solenoid Lock Plate
      GTY106757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) 

      HINT: 

      Install the solenoid lock plate into the cutout on the transfer control solenoid.

  5. INSTALL TRANSFER DRIVE SPROCKET BEARING 
    1. Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket.
      Fig 8: Installing Transfer Drive Sprocket Bearing Using SST (1 Of 2)
      GTY103456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-70010 
        • 09951-07100
      • SST: 09950-60010 
        • 09951-00640
      • SST: 09316-20011 
    2. Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket.
      Fig 9: Installing Transfer Drive Sprocket Bearing Using SST (2 Of 2)
      GTY106790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-60011 
        • 09316-00011
      NOTE:

      Install the transfer drive sprocket bearing with the shield facing upward.

  6. INSTALL TRANSFER DRIVEN SPROCKET BEARING 
    1. Using SST and a press, install a new transfer driven sprocket bearing to the transfer front driven clutch sleeve.
      Fig 10: Installing Transfer Driven Sprocket Bearing (1 Of 2)
      GTY106792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-70010 
        • 09951-07100
      • SST: 09950-60010 
        • 09951-00640
      • SST: 09316-20011 
    2. Using SST and a press, install a new transfer driven sprocket bearing to the transfer front driven clutch sleeve.
      Fig 11: Installing Transfer Driven Sprocket Bearing (2 Of 2)
      GTY106793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-60011 
        • 09316-00011
        • 09316-00041
  7. INSTALL TRANSFER CENTER SUPPORT SEAL RING 
    1. Coat the 2 seal rings with ATF.
      Fig 12: Compressing Transfer Center Support Seal Rings
      GTY106927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Compress the 2 transfer center support seal rings as shown in the illustration and install them into the grooves on the transfer center support.
      NOTE:
      • Do not expand the ring ends excessively.
      • If any ring is damaged or deformed, replace it with a new one.
  8. INSTALL TRANSFER CENTER SUPPORT 
    1. Install the transfer center support to the transfer chain case rear with the 5 bolts.
      Fig 13: Identifying Transfer Center Support
      GTY103463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

    2. Coat 2 new O-rings with ATF.
    3. Install the 2 O-rings to the screws.
    4. Install the 2 gaskets and 2 screws to the transfer chain case rear.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

  9. INSTALL TRANSFER DIRECT CLUTCH PISTON O-RING 
    1. Coat 2 new O-rings with ATF.
      Fig 14: Identifying Transfer Direct Clutch Piston O-Ring
      GTY102177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 O-rings to the transfer direct clutch piston.
      O-RING SIZE:

      Installation position Inner diameter mm (in.) Thickness mm (in.)
      Inner 56.45 to 57.45 (2.222 to 2.262) 2.54 to 2.70 (0.100 to 0.106)
      Outer 116.20 to 117.80 (4.575 to 4.638) 3.0 to 3.2 (0.118 to 0.126)
  10. INSTALL CENTER DIFFERENTIAL CLUTCH PISTON 
    1. Install the center differential clutch piston to the transfer direct clutch drum.
      Fig 15: Identifying Center Differential Clutch Piston
      GTY102977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the O-rings.

  11. INSTALL TRANSFER DIRECT CLUTCH RETURN SPRING 
    1. Install the transfer direct clutch return spring to the transfer direct clutch drum.
      Fig 16: Identifying Transfer Direct Clutch Return Spring
      GTY103315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER 
    1. Coat the rubber on the center differential clutch pressure balancer with ATF.
      Fig 17: Coating Rubber On Center Differential Clutch Pressure Balancer With ATF
      GTY106796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the center differential clutch pressure balancer to the transfer direct clutch drum.
    3. Place SST on the center differential clutch pressure balancer, and compress the return spring with a press.
      Fig 18: Installing Snap Ring
      GTY101707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-30020 
        • 09350-07040
    4. Using SST, install the snap ring.
      • SST: 09350-30020 
        • 09350-07040
        • 09350-07070
  13. INSTALL CENTER DIFFERENTIAL CLUTCH DISC SET 
    1. Install the 2 center differential clutch disc flanges and center differential clutch disc set to the transfer direct clutch drum.
      Fig 19: Identifying Center Differential Clutch Disc Set
      GTY101096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • A: Center differential clutch disc flange (No. 1)
      • B: Center differential clutch disc set (Discs)
      • C: Center differential clutch disc set (Plates)
      • D: Center differential clutch disc flange (No. 2)

      Install in the following order

      A - B - C - B - C - B - C - B -C - B - D

      HINT: 

      • A: thickness 2.95 to 3.45 mm (0.116 to 0.136 in.)
      • B: thickness 1.99 to 2.09 mm (0.078 to 0.082 in.)
      • C: thickness 1.95 to 2.05 mm (0.077 to 0.081 in.)
      • D: thickness 2.95 to 3.05 mm (0.116 to 0.120 in.)
      NOTE:

      Before assembling new discs, soak them in ATF for at least 15 minutes.

    2. Using a screwdriver with its tip taped, install the snap ring to the transfer direct clutch drum.
      Fig 20: Installing Snap Ring
      GTY104454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transfer direct clutch drum to the transfer center support.
      Fig 21: Identifying Transfer Direct Clutch Drum And Transfer Center Support
      GTY100070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Set the dial indicator perpendicular to the flange.
      Fig 22: Measuring Pack Clearance
      GTY102619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply air (200 kpa, 2.0 kgf*cm2 , 19 psi) at the oil hole as shown in the illustration. Measure the pack clearance.

      Standard

      0.40 to 0.80 mm (0.016 to 0.031 in.)

      HINT: 

      • Check that the piston moves smoothly.
      • Perform the measurement at 2 or 3 points and take the average.
    6. If the clearance is not within the specified range, select another center differential clutch disc flange (No. 1).
      Fig 23: Identifying Clutch Flange Thickness
      GTY107040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      FLANGE THICKNESS:

      Thickness mm (in.) Mark
      2.95 to 3.05 (0.116 to 0.120) 90
      3.15 to 3.25 (0.124 to 0.128) 91
      3.35 to 3.45 (0.132 to 0.136) 92
    7. Remove the transfer direct clutch drum from the transfer center support.
      Fig 24: Identifying Transfer Direct Clutch Drum And Transfer Center Support
      GTY100070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL TRANSFER REAR OUTPUT SHAFT BEARING 
    1. Install the transfer rear output shaft bearing to the transfer direct clutch drum.
      Fig 25: Identifying Transfer Rear Output Shaft Bearing
      GTY106795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL TRANSFER REAR OUTPUT SHAFT AND CENTER DIFFERENTIAL CARRIER 
    1. Install the transfer rear output shaft and center differential carrier to the transfer direct clutch drum.
      Fig 26: Identifying Center Differential Carrier
      GTY106797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL TRANSFER CASE FRONT OIL SEAL 
    1. Using SST and a hammer, install a new oil seal.
      Fig 27: Installing Transfer Case Front Oil Seal
      GTY106798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-60011 
        • 09316-00011
        • 09316-00071

      Oil seal drive in depth

      5.6 to 6.2 mm (0.220 to 0.244 in.)

    2. Apply MP grease to the oil seal lip.
  17. INSTALL TRANSFER CHAIN CASE GOVERNOR APPLY GASKET 
    1. Coat 2 new gaskets with ATF.
      Fig 28: Identifying Transfer Chain Case Governor Apply Gasket
      GTY106928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 gaskets to the transfer chain case rear.
    3. Coat a new O-ring and 2 new gaskets with ATF.
      Fig 29: Identifying Gaskets And Screw To Transfer Chain Case
      GTY106787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the O-ring to the screw.
    5. Install the 2 gaskets and screw to the transfer chain case front.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

  18. INSTALL TRANSFER BAFFLE VALVE SUB-ASSEMBLY 
    1. Install the transfer baffle valve to the transfer chain case rear with the bolt.
      Fig 30: Locating Bolt And Transfer Baffle Valve
      GTY106786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  19. INSTALL TRANSFER CASE BEARING 
    1. Using SST and a press, install the transfer case bearing to the transfer case.
      Fig 31: Installing Transfer Case Bearing
      GTY101497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60020 
        • 09951-00890
      • SST: 09950-70010 
        • 09951-07150

      Bearing drive in depth

      94.6 to 94.9 mm (3.724 to 3.736 in.)

  20. INSTALL TRANSFER CASE REAR OIL SEAL 
    1. Using SST and a hammer, install a new oil seal.
      Fig 32: Identifying Transfer Case Rear Oil Seal Using SST And Hammer
      GTY106761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09325-40010 

      Oil seal drive in depth

      2.3 to 2.7mm (0.091 to 0.106 in.)

    2. Apply MP grease to the oil seal lip.
    3. Install the clamp to the transfer case with the bolt.
      Fig 33: Locating Bolt And Clamp
      GTY101631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  21. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR 
    1. Using SST and a press, install a new transfer extension housing dust deflector to the transfer case.
      Fig 34: Installing Transfer Extension Housing Dust Deflector
      GTY103202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-70010 
        • 09951-07150
      • SST: 09950-60020 
        • 09951-00910
  22. INSTALL TRANSFER CHAIN CASE FRONT 
    1. Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol.
      Fig 35: Applying Seal Packing To Front Transfer Chain Case
      GTY106802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing to the transfer chain case front as shown in the illustration.

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    3. Temporarily tighten the 6 bolts in several steps, and then tighten to the specified torque.
      Fig 36: Identifying Tightening Bolts
      GTY101892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf) 

      HINT: 

      Bolt length: 

      • Bolt A: 57 mm (2.24 in.)
      • Bolt B: 74 mm (2.91 in.)
      • Other bolts: 45 mm (1.77 in.)
  23. INSTALL TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVE SPROCKET ASSEMBLY AND TRANSFER FRONT DRIVEN CLUTCH SLEEVE ASSEMBLY 
    1. Install the transfer front drive chain to the transfer drive sprocket and transfer front driven clutch sleeve.
      Fig 37: Identifying Transfer Front Drive Chain
      GTY106754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transfer front drive chain, transfer drive sprocket and transfer front drive clutch sleeve.
  24. INSTALL TRANSFER CHAIN CASE REAR 
    1. Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol.
      Fig 38: Applying Seal Packing To Transfer Chain Case Front
      GTY106801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing to the transfer chain case front as shown in the illustration.

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    3. Temporarily tighten the 10 bolts in several steps, and then tighten to the specified torque.
      Fig 39: Identifying Tightening Bolts
      GTY106752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf) 

      HINT: 

      Bolt length: 

      • Bolt A: 60 mm (2.36 in.)
      • Bolt B: 50 mm (1.97 in.)
      • Bolt C: 109 mm (4.29 in.)
      • Other bolts: 40 mm (1.57 in.)
  25. INSTALL FLANGE YOKE 
    1. Install the flange yoke.
    2. Using SST, hold the yoke.
      Fig 40: Holding Yoke Using SST
      GTY102941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09213-54015 
      • SST: 09330-00021 
    3. Using a deep socket wrench (30 mm), torque the nut.

      Torque: 123 N*m (1,254 kgf*cm, 91 ft.*lbf) 

    4. Using a chisel and hammer, stake the nut.
  26. INSTALL TRANSFER REAR OUTPUT SHAFT ASSEMBLY 
    1. Install the transfer rear output shaft.
      Fig 41: Identifying Transfer Rear Output Shaft Assembly
      GTY102071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL TRANSFER CASE 
    1. Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol.
      Fig 42: Applying Seal Packing To Transfer Chain Case Front
      GTY106800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing to the transfer chain case front as shown in the illustration.

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    3. Temporarily tighten the 8 bolts and clamp in several steps, and then tighten to the specified torque.
      Fig 43: Locating Transfer Case Bolts And Clamp
      GTY100466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf) 

      HINT: 

      Bolt length: 

      • Bolt A: 88 mm (3.46 in.)
      • Bolt B: 40 mm (1.57 in.)
  28. INSTALL TRANSFER VALVE BODY ASSEMBLY 
    1. Coat the transfer wire O-ring with ATF.
      Fig 44: Identifying Transfer Wire O-Ring
      GTY107054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transfer wire with the bolt.
      Fig 45: Identifying Transfer Wire With Bolt
      GTY100994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    3. Connect the transfer wire connector to the transfer control solenoid.
      Fig 46: Locating Transfer Valve Body Assembly Bolts
      GTY106750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the transfer valve body assembly with the 4 bolts.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  29. INSTALL TRANSFER OIL PAN 
    1. Install the transfer oil cleaner magnet to the transfer oil pan.
      Fig 47: Identifying Transfer Oil Cleaner Magnet
      GTY101194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol.
      Fig 48: Applying Seal Packing To Transfer Chain Case Front
      GTY106799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply seal packing to the transfer chain case front as shown in the illustration.

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    4. Temporarily tighten the 9 bolts in several steps, and then tighten to the specified torque.
      Fig 49: Locating Transfer Oil Pan Bolts
      GTY101408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

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