Disassembly [08/2015 - ]: Procedure

1. Detach the clamp and remove the hose.

1. Remove the 5 bolts and bearing retainer.

   HINT: 

   If necessary, tap the bearing retainer with a plastic-faced hammer to remove it.

1. Using a screwdriver and hammer, remove the oil seal from the bearing retainer.

1. Remove the 4 bolts and case cover.

1. Remove the oil deflector.

1. Using a chisel and hammer, loosen the staked part of the lock nut.
2. Using SST to hold the companion flange, remove the lock nut.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09330-00021 
3. Using SST, remove the companion flange.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09950-40011 
     1. 09951-04020
     2. 09952-04010
     3. 09953-04030
     4. 09954-04010
     5. 09955-04051
     6. 09957-04010
     7. 09958-04011

1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.
   NOTE:

   Be careful not to damage the oil seal and companion flange contact surfaces.

See step  5

1. Using a chisel and hammer, loosen the staked part of the lock nut.
2. Using SST to hold the companion flange, remove the lock nut.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09330-00021 
3. Using SST, remove the companion flange.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09950-40011 
     1. 09951-04020
     2. 09952-04010
     3. 09953-04030
     4. 09954-04010
     5. 09955-04051
     6. 09957-04010
     7. 09958-04011

1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.
   NOTE:

   Be careful not to damage the oil seal and companion flange contact surfaces.

See step  5

1. Remove the 5 bolts and extension housing.

   HINT: 

   If necessary, tap the extension housing with a plastic-faced hammer to remove it.

1. Remove the 2 washers.

1. Remove the collar.

1. Remove the 12 bolts and clamp.
2. Remove the rear transfer case.

   HINT: 

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

1. Remove the bolt, No. 2 gear shift fork, and high and low clutch sleeve.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using 2 screwdrivers and a hammer, tap off the snap ring.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Remove the bolt, center differential lock fork and front drive clutch sleeve.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Mount the rear transfer case in a vise.
2. Using a snap ring expander, remove the snap ring.
3. Using a plastic-faced hammer, carefully tap the rear transfer case, and remove the rear output shaft together with the front drive chain and driven sprocket.
4. Remove the rear output shaft, front drive chain and driven sprocket.

1. Using SST and a press, remove the driven sprocket bearing.
   • SST: 09555-55010 

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Be careful not to drop or damage the driven sprocket.

1. Using SST and a press, remove the transfer input gear radial ball bearing.
   • SST: 09555-55010 

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Be careful not to drop or damage the driven sprocket.

1. Using 2 screwdrivers and a hammer, tap off the 2 snap rings.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Remove the 3 bolts and transfer shift actuator.
3. Remove the O-ring from the transfer shift actuator assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the filler plug and gasket.

1. Remove the drain plug and gasket.

1. Remove the 3 bolts and oil separator.

1. Remove the 3 bolts and oil pump body.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the oil pump body O-ring.
   NOTE:

   Be careful not to damage the oil pump body.

1. Remove the transfer oil pump gear.

1. Using a snap ring expander, remove the snap ring.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Remove the low planetary gear together with the input shaft.

1. Remove the transfer output shaft spacer.

1. Remove the needle roller bearing.

1. Using a snap ring expander, remove the snap ring.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the input gear stopper.

1. Remove the ball.

1. Remove the washer.

1. Remove the transfer input shaft.

1. Remove the thrust bearing race.

1. Remove the bearing.

1. Remove the 2 seal rings.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a snap ring expander, remove the snap ring.
2. Using SST and a press, remove the input shaft bearing.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09555-55010 
   • SST: 09950-70010 
     1. 09951-07150
   • SST: 09950-60020 
     1. 09951-00750
   NOTE:

   Be careful not to drop or damage the low planetary gear.

1. Using a screwdriver, remove the snap ring.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Remove the low planetary gear spline piece.

1. Using SST, remove the low planetary gear bearing.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09612-65014 
     1. 09612-01030
     2. 09612-01050
   NOTE:

   Make sure SST fits securely in the space between the bearing and low planetary gear.

1. Using a snap ring expander, remove the snap ring.
2. Remove the spacer.

1. Remove the ball.

1. Remove the center differential case.

1. Remove the transfer clutch hub.

1. Remove the needle roller bearing.

1. Remove the washer.

1. Using SST and a press, remove the bearing.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09555-55010 

1. Remove the output shaft spacer.

1. Remove the transfer drive sprocket.

1. Remove the bearing.

1. Remove the washer.

1. Remove the transfer case plug.

1. Remove the spring.

1. Remove the pin.

1. Using a screwdriver, remove the snap ring.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Remove the low planetary ring gear from the front transfer case.