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Transfer Unit: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE TRANSFER COVER GASKET 
    1. Remove the transfer gasket from the transfer assembly.
      Fig 1: Removing Transfer Cover Gasket
      G04497636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE TRANSFER CASE BREATHER PLUG 
    1. Using a screwdriver and a hammer, remove the transfer case breather plug from the No. 1 transfer case cover.
      NOTE: Be careful not to damage the contact surface of No. 1 case cover.
      Fig 2: Removing Transfer Case Breather Plug
      G04497637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE NO. 1 TRANSFER CASE COVER 
    1. Remove the 8 bolts.
      Fig 3: Removing Transfer Case Cover Bolts
      G04497638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the No. 1 transfer case cover from the transfer case.
      NOTE: Be careful not to damage the contact surfaces of the case and cover.
      Fig 4: Removing Transfer Case Cover From Transfer Case
      G04497639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE BREATHER OIL DEFLECTOR 
    1. Remove the bolt and breather oil deflector from the No. 1 transfer case cover.
      Fig 5: Removing Breather Oil Deflector
      G04497640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSFER DYNAMIC DAMPER 
    1. Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing sub-assembly.
  6. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 4 transfer case straight pins from the transfer case.
  7. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. Remove the 4 transfer and transaxle setting stud bolts.
      Fig 6: Removing Transfer Dynamic Damper
      G04497641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. FIX TRANSFER ASSEMBLY 
    1. Fix the transfer assembly to the overhaul attachment.
  9. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR 
    1. Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.
      Fig 7: Removing Transfer Extension Housing Dust Deflector
      G04497642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST(s), remove the transfer extension housing type T oil seal from the transfer extension housing.

      SST 09308-00010 

      NOTE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.
      Fig 8: Removing Transfer Extension Housing Type T Oil Seal
      G04497643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 4 bolts.
      Fig 9: Removing Transfer Extension Housing Sub-Assembly Bolts
      G04497644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the transfer extension housing sub- assembly from the transfer case.
      Fig 10: Removing Transfer Extension Housing Sub-Assembly
      G04497645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT PRELOAD 
    1. Using SST(s) and a torque wrench, check the initial torque with the backlash range.

      SST 09326-20011 

      Torque: 0.9 to 1.4 N*m (9 to 14 kgf*cm, 8.0 to 12.4 in.*lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)

    2. Using SST(s) and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.

      SST 09326-20011 

      Torque: Preload 

      + 0.15 to 0.30 N*m (+ 1.6 to 3.1 kgf*cm, + 1.3 to 2.7 in.*lbf) 

      Fig 11: Checking Driven Pinion Preload
      G04497646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)

  13. REMOVE CTR DIFFERENTIAL LOCK SLEEVE 
    1. Using snap ring pliers, remove the shaft snap ring.
      Fig 12: Removing Shaft Snap Ring
      G04497647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST(s), remove the CTR differential lock sleeve.

      SST 09308-00010 

      Fig 13: Removing CTR Differential Lock Sleeve
      G04497648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE O-RING 
    1. Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.
      NOTE: Be careful not to damage the lock sleeve's groove for the O-ring.
      Fig 14: Removing O-Ring
      G04497649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSFER CASE OIL SEAL 
    1. Using SST(s), remove the transfer case oil seal from the case.

      SST 09308-00010 

      NOTE: Be careful not to damage the oil-seal-fitted surface of the case.
      Fig 15: Removing Transfer Case Oil Seal
      G04497650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST(s), remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.

      SST 09308-00010 

      NOTE: Be careful not to damage the oil-seal-fitted surface of the retainer.
      Fig 16: Removing Transfer RH Bearing Retainer Oil Seal
      G04497651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY 
    1. Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.
      Fig 17: Removing Transfer RH Bearing Retainer Sub-Assembly Bolts
      G04497652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver and a hammer, create a clearance between the transfer RH bearing retainer sub-assembly and the transfer case.
      NOTE: Be careful not to damage the transfer RH bearing retainer sub-assembly and the transfer case.
      Fig 18: Making Clearance Between Transfer RH Bearing Retainer Sub-Assembly And Transfer Case
      G04497653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST(s), remove the transfer RH bearing retainer sub-assembly from the transfer case.

      SST 09520-10021 

      Fig 19: Removing Transfer RH Bearing Retainer Sub-Assembly From Transfer Case
      G04497654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE O-RING 
    1. Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assembly.
      NOTE: Be careful not to damage the retainer's grooves for the O-rings.
      Fig 20: Removing O-Rings From Transfer RH Bearing Retainer Sub-Assembly
      G04497655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Fix the transfer RH bearing retainer sub-assembly in a vise.
    2. Using SST(s), remove the center differential case tapered roller bearing RH outer race, transfer ring gear mounting case washer No. 2 and right bearing retainer oil seal No. 2 from the transfer RH bearing retainer sub-assembly.

      SST 09308-00010 

      NOTE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer subassembly.
      Fig 21: Removing Center Differential Case Tapered Roller Bearing
      G04497656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE SIDE GEAR SHAFT HOLDER BEARING 
    1. Using snap ring pliers, remove the side gear shaft holder hole snap ring.
    2. Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assembly.
      Fig 22: Removing Side Gear Shaft Holder Hole Snap Ring
      G04497657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSFER RING GEAR MOUNTING CASE 
    1. Remove the transfer ring gear mounting case from the transfer case.
      Fig 23: Removing Transfer Ring Gear Mounting Case
      G04497658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
      NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
      Fig 24: Attaching SST To Inner Race Of Center Differential Case Tapered Roller Bearing
      G04497659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
      NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
      Fig 25: Removing Inner Race Of Center Differential Case Tapered Roller Bearing
      G04497660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
      NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
      Fig 26: Attaching SST To Center Differential Case Tapered Roller Bearing
      G04497661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
      NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
      Fig 27: Removing Center Differential Case Tapered Roller Bearing
      G04497662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE RING GEAR 
    1. Put matchmarks on the transfer ring gear mounting case and the ring gear.
    2. Remove the 12 bolts.
      Fig 28: Identifying Matchmarks On Transfer Ring Gear Mounting Case And Ring Gear
      G04497663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, remove the ring gear by tapping around its periphery.
      NOTE: Do not damage the teeth of the ring gear.
      Fig 29: Removing Ring Gear
      G04497664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSFER GEAR NUT 
    1. Using SST(s) and a hammer, unstake the transfer gear nut.

      SST 09930-00010 

      Fig 30: Unstaking Transfer Gear Nut
      G04497665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST(s), remove the transfer gear nut.
      Fig 31: Removing Transfer Gear Nut
      G04497666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer.
      NOTE:
      • Put shop cloths around to help prevent the driven pinion from bearing dropped.
      • Place something like wood blocks under the case to keep it level.
        Fig 32: Removing Transfer Driven Pinion, Driven Pinion Rear Bearing Inner Race And Spacer
        G04497667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST(s) and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.

      SST 09950-00020 

      Fig 33: Removing Transfer Driven Pinion Front Bearing
      G04497668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 positions to remove it from the transfer case.
      Fig 34: Removing Center Differential Case Tapered Roller Bearing
      G04497669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE TRANSFER OUTPUT WASHER 
    1. Remove the ring gear mounting case plate washer from the transfer case.
  28. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.
  29. REMOVE RING GEAR MOUNTING CASE PLATE WASHER 
    1. Remove the transfer output washer from the transfer case.
      Fig 35: Removing Center Differential Case Tapered Roller Bearing
      G04497670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE TRANSFER DRIVEN PINION REAR BEARING 
    1. Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.
      Fig 36: Removing Transfer Driven Pinion Rear Bearing
      G04497671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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