Transfer Unit: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSTALL TRANSFER DRIVEN PINION REAR BEARING
1. Using SST(s) and a press, install the transfer driven pinion rear bearing outer race to the transfer case.
  SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
  
  NOTE: Place something like wood blocks under the case to keep its level.
  
  Fig 1: Installing Transfer Driven Pinion Rear Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OUTPUT WASHER
1. Install the transfer output washer to the transfer case.
  HINT:
  
  Reuse the washer.
INSTALL TRANSFER DRIVEN PINION FRONT BEARING
1. Install the transfer driven pinion front bearing outer race to the transfer case with SST(s), bolt and nut.
  SST 09950-60020 (09951-00750, 09951-00770, 09951-00810), 09316-60011 (09316-00061)
  
  Fig 2: Installing Transfer Driven Pinion Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RING GEAR MOUNTING CASE PLATE WASHER
1. Install the ring gear mounting case plate washer to the transfer case.
  HINT:
  
  Reuse the washer.
INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using SST(s) and a press, install the center differential case tapered roller bearing LH outer race to the transfer case.
  SST 09950-70010 (09951-07200), 09316-60011 (09316-00021)
  
  Fig 3: Installing Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DRIVEN PINION FRONT BEARING
1. Using SST(s) and a press, install the transfer driven pinion front bearing inner race to the driven pinion.
  
  Fig 4: Installing Transfer Driven Pinion Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVEN PINION
1. Install the driven pinion to the transfer case.
  
  Fig 5: Installing Driven Pinion To Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new transfer pinion bearing spacer and anew transfer driven pinion rear bearing inner race to the driven pinion.
  
  Fig 6: Installing Transfer Pinion Bearing Spacer And Inner Race To Driven Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST(s), tighten a new transfer gear nut (at a standard torque.)
  SST 09326-20011, 09556-16030
  
  Torque: 277 to 378 N*m (2,820 to 3,855 kgf*cm, 204 to 279 ft.*lbf)
  
  NOTE: Do not stake the transfer gear nut.
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 750 mm (29.53 in.)
  
  Fig 7: Tightening Transfer Gear Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT AND ADJUST DRIVEN PINION PRELOAD
1. Using SST(s) and a torque wrench, measure thee initial torque of the driven pinion.
  SST 09326-20011, 09556-16030
  
  Torque: New bearing
  
  1.1 to 1.6 N*m (10 to 16 kgf*cm, 9.7 to 14.2 in.*lbf)
  
  Used bearing
  
  0.9 to 1.4 N*m (9 to 14 kgf*cm, 8.0 to 12.4 in.*lbf)
  
  Fig 8: Checking Driven Pinion Preload
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 160 mm (6.30in.)
  
  NOTE: Measure preload after rotating the bearing both clockwise and counterclockwise to make it fit.
2. If the preload is too large, replace the transfer pinion bearing spacer with a new one.
3. If the preload is too small, repeatedly adjust the preload by tightening the transfer gear nut 5 to 10 degrees at a time until the standard value is obtained.
4. If the preload is insufficient, even though the tightening torque of the transfer gear nut exceeds the maximum of the standard value, loosen the transfer gear nut and apply gear oil SAE 90 (GL-5) to the transfer gear nut and the screw thread and the base of driven pinion. And then repeat the preceding operation. If the tightening torque is bearing spacer with anew one and adjust it.
  Torque: 378 N*m (3.855 kgf*cm, 279 ft.*lbf)
INSTALL RING GEAR
1. Heat the ring gear in boiling water from 90 to 100 °C (194 to 212 °F).
2. Completely remove grease and moisture on the contact surfaces of the ring gear and the transfer ring gear mounting case.
  
  Fig 9: Heating Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the matchmarks on the ring gear and transfer ring gear mounting case and quickly assemble them.
4. Tighten the 12 bolts.
  Torque: 78 N*m (790 kgf*cm, 57 ft.*lbf)
  NOTE:
  - Tighten the bolts in diagonal order in splitting several times.
  - After the ring gear has well cooled down, fully tighten the bolts.
  - Make the bolt heads in order to check if they are retightened or not.
    
    Fig 10: Identifying Matchmarks On Transfer Ring Gear Mounting Case And Ring Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using SST(s) and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case.
  SST 09506-35010, 09950-60010 (09951-00430), 09223-00010
  
  NOTE: When replacing the inner race, replace it together with the outer race.
  
  Fig 11: Installing Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER RING GEAR MOUNTING CASE
1. Install the transfer ring gear mounting case to the transfer case.
  NOTE: Damage to the spline, the bearing's rotating surface and gear face may cause a decrease in their strength. Care should be taken when installing them.
INSTALL NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER
1. Install the No. 2 transfer ring gear mounting case washer to the transfer RH bearing retainer subassembly.
  HINT:
  
  Reuse the washer.
  
  Fig 12: Installing Transfer Ring Gear Mounting Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using SST(s) and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer subassembly.
  SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
  
  Fig 13: Installing Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY
1. Place the transfer the face where the transfer RH bearing retainer sub-assembly is to be installed facing up.
2. Center-align the transfer ring gear mounting case and the transfer case.
  
  Fig 14: Aligning Centers Of Transfer Ring Gear Mounting Case And Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the SST(s) into the transfer RH bearing retainer sub-assembly.
  NOTE: Insert SST(s) straight in order not to damage the oil seal lip.
  
  Fig 15: Installing SST Into Transfer RH Bearing Retainer Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert the transfer RH bearing retainer subassembly together with the SST(s) into the transfer case.
  NOTE: Interference between the case and retainer, and between the transfer ring gear mounting case and SST(s) should be carefully avoided.
  
  HINT:
  
  If the retainer cannot be inserted, tap it in with a plastic hammer.
  
  Fig 16: Inserting Transfer RH Bearing Retainer Subassembly With SST Into Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. After inserting the transfer RH bearing retainer subassembly into the transfer case, remove the SST(s).
6. Tighten the 7 bolts.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  Fig 17: Installing Transfer RH Bearing Retainer Sub-Assembly With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT DIFFERENTIAL RING GEAR BACKLASH

Set the dial gauge perpendicular to the ring gear face, fix the driven pinion, and check backlash by moving the ring gear.
Backlash:

0.10 to 0.15 mm (0.0039 to 0.0059 in.)

NOTE: Measure it at 3 points or more on the ring gear periphery.

If the measured value is out of standard, select a proper washer for the center differential case tapered roller bearing on the LH side from the table below and install it to obtain the standard value.

Fig 18: Checking Differential Ring Gear Backlash

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WASHER THICKNESS SPECIFICATION (1 OF 3)

Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
AA	2.07 (0.0814)	AB	2.10 (0.0826)	AC	2.13 (0.0838)
BA	2.16 (0.0850)	BB	2.19 (0.0862)	BC	2.22 (0.0874)
CA	2.25 (0.0885)	CB	2.28 (0.0897)	CC	2.31 (0.0909)
DA	2.34 (0.0921)	DB	2.37 (0.0933)	DC	2.40 (0.0944)
EA	2.43 (0.0956)	EB	2.46 (0.0968)	EC	2.49 (0.0980)
FA	2.52 (0.0992)	FB	2.55 (0.1003)	FC	2.58 (0.1015)
GA	2.61 (0.1027)	GB	2.64 (0.1039)	GC	2.67 (0.1051)
HA	2.70 (0.1062)	HB	2.73 (0.1074)	HC	2.76 (0.1086)
JA	2.79 (0.1098)	JB	2.82 (0.1110)	JC	2.85 (0.1122)
KA	2.88 (0.1133)	KB	2.91 (0.1145)	KC	2.94 (0.1157)
LA	2.97 (0.1169)	LB	3.00 (0.1181)

HINT:

When the backlash is larger or smaller than the standard, select a thinner or thicker washer respectively.

Ring gear mounting case plate washer location is shown in Fig 19.

Fig 19: Locating Ring Gear Mounting Case Plate Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate it several times.

Fig 20: Applying Red Lead Primer On Ring Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Check the tooth contact on the ring gear at 4 places or more.
Observe the pattern shown by red lead primer.

Fig 21: Identifying Ring Gear And Drive Pinion Tooth Contact Pattern
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

In case of poor tooth contact, select a washer for the driven pinion bearing front side from the following table and replace it.

NOTE: If the washer thickness is changed, the backlash will be also changed.

WASHER THICKNESS SPECIFICATION (2 OF 3)

Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
AA	1.20 (0.0472)	AC	1.22 (0.0480)	BB	1.24 (0.0488)
CA	1.26 (0.0496)	CC	1.28 (0.0503)	DB	1.30 (0.0511)
EA	1.32 (0.0519)	EC	1.34 (0.0527)	FB	1.36 (0.0535)
GA	1.38 (0.0543)	GC	1.40 (0.0551)	HB	1.42 (0.0559)
JA	1.44 (0.0566)	JC	1.46 (0.0574)	KB	1.48 (0.0582)
LA	1.50 (0.0590)	LC	1.52 (0.0598)	MB	1.54 (0.0606)
NA	1.56 (0.0614)	NC	1.58 (0.0622)	PB	1.60 (0.0629)
QA	1.62 (0.0637)	QC	1.64 (0.0645)

The location of the transfer output washer for tooth contact adjustment is shown in Fig 22.

Fig 22: Locating Transfer Output Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST TOTAL PRELOAD

Using SST(s) and a torque wrench, measure the initial torque with the driven pinion bearing contact with the ring gear face.
SST 09326-20011

Torque: New bearing

+0.2 to 0.4 N*m (+2.3 to 3.9 kgf*cm, 1.8 to 3.5 in.*lbf)

Used bearing

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

NOTE: Before measurement, rotate the bearing in both directions several times to make it fit.

Fig 23: Checking Total Preload Of Drive Pinion
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

If the value is out of standard range, select the washer for the center differential case tapered roller bearing RH side from the following table and replace it.

WASHER THICKNESS SPECIFICATION (3 OF 3)

Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
AA	1.47 (0.0578)	AB	1.50 (0.0590)	AC	1.53 (0.0602)
BA	1.56 (0.0614)	BB	1.59 (0.0625)	BC	1.62 (0.0637)
CA	1.65 (0.0649)	CB	1.68 (0.0661)	CC	1.71 (0.0673)
DA	1.74 (0.0685)	DB	1.77 (0.0696)	DC	1.80 (0.0708)
EA	1.83 (0.0720)	EB	1.86 (0.0732)	EC	1.89 (0.0744)
FA	1.92 (0.0755)	FB	1.95 (0.0767)	FC	1.98 (0.0779)
GA	2.01 (0.0790)	GB	2.04 (0.0803)	GC	2.07 (0.0814)
HA	2.10 (0.0826)	HB	2.13 (0.0838)	HC	2.16 (0.0850)
JA	2.19 (0.0862)	JB	2.22 (0.0874)	JC	2.25 (0.0885)
KA	2.28 (0.0897)	KB	2.31 (0.0909)	KC	2.34 (0.0921)
LA	2.37 (0.0933)	LB	2.40 (0.0944)	LC	2.43 (0.0956)
MA	2.46 (0.0968)	MB	2.49 (0.0980)	MC	2.52 (0.0992)
NA	2.55 (0.1003)	NB	2.58 (0.1015)

The location of the transfer ring gear mounting case washer No. 2 for preload adjustment is shown in Fig 24.

Fig 24: Locating Transfer Ring Gear Mounting Case Washer No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a chisel, stake the transfer gear nut.

Fig 25: Staking Transfer Gear Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY
1. remove the 7 bolts from the transfer RH bearing retainer sub-assembly.
  
  Fig 26: Removing Transfer RH Bearing Retainer Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver and a hammer, make a opening between the transfer RH bearing retainer subassembly
  NOTE: Be careful not to damage the transfer RH bearing retainer sub-assembly and the transfer case.
  
  Fig 27: Making Clearance Between Transfer RH Bearing Retainer Sub-Assembly And Transfer Case
  Courtesy 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 28: Removing Transfer RH Bearing Retainer Sub-Assembly From Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 and transfer ring gear mounting case washer No. 2 from the transfer RH bearing retainer sub-assembly.
  SST 09308-00010
  
  Fig 29: Removing Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SIDE GEAR SHAFT HOLDER BEARING
1. Install the side gear shaft holder bearing to the transfer RH bearing retainer sub-assembly.
2. Using snap ring pliers, install the side gear shaft holder hole snap ring.
  HINT:
  
  Check that the side gear shaft holder hole snap ring fits in the groove of the transfer RH bearing retainer sub-assembly.
  
  Fig 30: Installing Side Gear Shaft Holder Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
1. Using SST(s) and a press, install the transfer RH bearing retainer oil seal No. 2 to the transfer RH bearing retainer sub-assembly.
  SST 09950-60010 (09951-00350, 09951-00560, 09952-06010), 09950-70010 (09951-07150)
  
  NOTE: Carefully press-fit so that the oil seal will not be tilted.
2. Apply small amount of MP grease No. 2 to the oil seal lip.
  
  Fig 31: Installing Transfer RH Bearing Retainer Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER
1. Install the No. 2 selected transfer ring gear mounting washer to the transfer RH bearing retainer sub-assembly.
INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using SST(s) and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer subassembly.
  SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
  
  Fig 32: Installing Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL O-RING
1. Coat the 2 O-rings with hypoid gear oil.
2. Install the 2 O-rings to the transfer RH bearing retainer sub-assembly.
  NOTE: Be careful not to twist the O-ring and fit it properly in the retainer's groove.
  
  Fig 33: Installing O-Rings To Transfer RH Bearing Retainer Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY
1. Place the transfer with the surface where the transfer RH bearing retainer sub-assembly is facing up.
2. Align the centers of the transfer ring gear mounting case and the transfer case.
  
  Fig 34: Aligning Centers Of Transfer Ring Gear Mounting Case And Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Insert SST(s) into the transfer RH bearing retainer sub-assembly.
  SST 09387-00090
  
  NOTE: Insert SST(s) straight in order not to damage the oil seal.
  
  Fig 35: Inserting SST Into Transfer RH Bearing Retainer Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert transfer RH bearing retainer sub-assembly together with SST(s) into the transfer case.
  NOTE:
  - Avoid interference between the case and the retainer, and between the SST(s) and the transfer ring gear mounting case.
  - Carefully check the retainer's O-ring for damage and incorrect fitting.
  HINT:
  
  If the retainer be inserted into the case, tap it in with a plastic hammer.
  
  Fig 36: Inserting Transfer RH Bearing Retainer Sub-Assembly With SST Into Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. After inserting transfer RH bearing retainer sub-assembly into the transfer case, remove the SST(s).
  
  Fig 37: Removing SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the 7 bolts.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  Fig 38: Installing Transfer RH Bearing Retainer Sub-Assembly With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TOTAL PRELOAD
1. Using SST(s) and a torque wrench, measure the initial torque with the driven pinion being in contact with the ring gear face.
  SST 09326-20011
  
  Torque: New bearing
  
  +0.2 to 0.4 N*m (+2.3 to 3.9 kgf*cm, 1.8 to 3.5 in.*lbf)
  
  Used bearing
  
  +0.15 to 0.30 N*m (+1.6 to 3.1 kgf*cm, 1.3 to 2.7 in.*lbf)
  
  Fig 39: Checking Total Preload Of Drive Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 160mm (6.30 in.)
INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
1. Using SST(s), install the transfer RH bearing retainer oil seal to the transfer RH bearing retainer sub-assembly to the position as shown in Fig 40.
  SST 09223-46011
  
  NOTE: Install the oil seal carefully so that it will not be tilted.
2. Apply MP grease to the oil seal lip.
  
  Fig 40: Installing Transfer RH Bearing Retainer Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE OIL SEAL
1. Using(s), install the transfer case oil seal to the transfer case at the position as shown in Fig 41.
  SST 09387-00010, 09950-70010 (09951-07150)
  
  NOTE: Install the oil seal carefully so that it will not be tilted.
2. Apply small amount of MP grease to the oil seal lip.
  
  Fig 41: Installing Transfer Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CTR DIFFERENTIAL LOCK SLEEVE
1. Coat a new O-ring with hypoid gear oil.
2. Install the O-ring to the CTR differential lock sleeve.
  NOTE: Be careful not to twist the O-ring and fit it properly in the retainer's groove.
  
  Fig 42: Installing O-Ring To CTR Differential Lock Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST(s), install the CTR differential lock sleeve to the transfer case.
  SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)
  
  Fig 43: Installing CTR Differential Lock Sleeve To Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using snap ring pliers, install the shaft snap ring.
  NOTE: Check that the snap ring is fitted in the groove of the ring gear mounting case.
  
  Fig 44: Installing Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
1. Using SST(s), install the transfer extension housing type T oil seal to the transfer extension housing at the position as shown in Fig 45.
  SST 09950-60010 (09951-00380, 09951-00580, 09951-07150, 09952-06010), 09950-70010
  
  NOTE: Install the oil seal carefully so that it will not be tilted.
  
  Fig 45: Installing Transfer Extension Housing Type T Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply small amount of MP grease No. 2 to the oil seal lip.
INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR
1. Using SST(s) and press, install a new transfer extension housing dust deflector to the transfer extension housing sub-assembly.
  SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
  
  Fig 46: Installing Transfer Extension Housing Dust Deflector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
1. Apply sealant 1281 to the transfer extension housing sub-assembly in continuous beaded from of 1.2 mm diameter as shown in Fig 47.
  NOTE:
  - Wipe any grease off from the attaching surfaces.
  - Install the transfer extension housing subassembly within 10 minutes after applying the sealant.
    
    Fig 47: Applying Sealant To Transfer Extension Housing Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transfer extension housing sub-assembly to the transfer case with the 4 bolts.
  Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
3. Remove the transfer assembly from the overhaul attachment.
  
  Fig 48: Installing Transfer Extension Housing Sub-Assembly To Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT
1. Install the transfer and transaxle setting stud bolts to the parts of the transfer case as shown in Fig 49.
  Torque: 39 N*m (400 kgf*cm, 30 ft.*lbf)
  
  NOTE: Install the sealant-coated side of the transfer and transaxle stud bolt to the transfer case.
  
  Fig 49: Identifying Sealant-Coated Part Of Transfer And Transaxle Setting Stud Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE STRAIGHT PIN
1. Using a plastic hammer, install the transfer case straight pins to the transfer case as shown in Fig 50.
  
  Fig 50: Installing Transfer Case Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DYNAMIC DAMPER
1. Install the transfer dynamic damper to the transfer extension housing sub-assembly with the 3 bolts.
  Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
  
  Fig 51: Installing Transfer Dynamic Damper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BREATHER OIL DEFLECTOR
1. Install the breather oil deflector to the transfer case cover No. 1 with the bolt.
  Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)
  
  NOTE: Be careful about the direction of the deflector's fold.
  
  Fig 52: Installing Breather Oil Deflector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSFER CASE COVER
1. Apply sealant 1281 to the transfer case cover No. 1 in a continuous bead of 1.2 mm diameter as shown in Fig 53.
  NOTE:
  - Wipe any grease off from the attaching surfaces.
  - Install the transfer case cover No. 1 within 10 minutes after application of the sealant.
    
    Fig 53: Applying Sealant To Transfer Case Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transfer case cover No. 1 to the transfer case with 8 bolts.
  Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
  
  Fig 54: Installing Transfer Case Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE BREATHER PLUG
1. Using SST(s) and a hammer, install the transfer case breather plug to the transfer case cover No. 1.
  SST 09612-10093 (09612-10061)
  
  Fig 55: Installing Transfer Case Breather Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER COVER GASKET
1. Install a new transfer cover gasket to the transfer case.
  
  Fig 56: Installing Transfer Cover Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002