Transfer Assembly: Disassembly

REMOVE BREATHER HOSE
REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR
1. Remove the bolt and driven gear.
REMOVE MOTOR ACTUATOR
1. Remove the 4 bolts and motor actuator.
  
  Fig 1: Removing 4 Bolts Of Motor Actuator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT GEAR

Fig 2: Removing Output Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SCREW PLUG
1. Using a T40 "torx" socket, remove the screw plug.
REMOVE SPRING
1. Using a magnetic finger, remove the spring.
REMOVE BALL
1. Using a magnetic finger, remove the ball.
REMOVE TRANSFER INDICATOR SWITCH
1. Remove the 3 indicator switches and 3 gaskets.
  
  Fig 3: Removing Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
1. Remove the 6 bolts and extension housing.
  HINT:
  
  If necessary, tap the extension housing lightly with a plastic-faced hammer.
  
  Fig 4: Removing Front Transfer Extension Housing Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH SLEEVE WITH NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK

Fig 5: Removing Clutch Sleeve With No. 2 Shift Fork Shaft & No. 2 Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK
1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the No. 2 shift fork shaft.
2. Separate the No. 2 shift fork shaft and No. 2 shift fork.
  
  Fig 6: Tapping Out 3 Snap Rings From No. 2 Shift Fork Shaft Using Screwdrivers & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
1. Remove the 9 bolts and extension housing.
  HINT:
  
  If necessary, tap the extension housing lightly with a plastic-faced hammer.
REMOVE ADJUSTING SHIM
1. Remove the adjusting shims.
  
  Fig 7: Removing Rear Transfer Extension Housing Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER ASSEMBLY
1. Remove the 2 bolts and oil strainer.
  
  Fig 8: Removing Bolts & Oil Strainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CASE COVER
1. Remove the 5 bolts.
  
  Fig 9: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap the case cover and remove it.
  
  Fig 10: Tapping Case Cover Using Brass Bar & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE FRONT CASE AND REAR CASE
1. Using a snap ring expander, remove the snap ring from the rear case.
  
  Fig 11: Removing Snap Ring From Rear Case Using Snap Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 8 bolts.
3. Using a brass bar and hammer, tap the rear case and separate it.
  
  Fig 12: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING RACE
1. Remove the 2 bearing races from the rear case.
  
  Fig 13: Removing Bearing Races From Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT SUB-ASSEMBLY
1. Using a plastic-faced hammer, remove the input shaft from the front case.
  
  Fig 14: Removing Input Shaft Sub-Assembly From Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, NO. 1 SHIFT FORK SHAFT AND NO. 1 SHIFT FORK
1. Remove the idler gear with center differential, No. 1 shift fork shaft and No. 1 shift fork from the front case.
  
  Fig 15: Removing Idler Gear With Center Differential, No. 1 Shift Fork Shaft & No. 1 Shift Fork From Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE NO. 1 SHIFT FORK SHAFT AND NO. 1 SHIFT FORK
1. Using a pin punch and hammer, tap out the slotted spring pin.
2. Separate the No. 1 shift fork and No. 1 shift fork shaft.
  
  Fig 16: Tapping Out Slotted Spring Pin Using Pin Punch & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTER SHIFT LEVER AND INNER SHIFT LEVER
1. Remove the nut and washer from the outer shift lever.
2. Using a brass bar, hammer and socket wrench, tap out the lever lock pin.
3. Remove the outer shift lever, washer and inner shift lever from the front case.
  
  Fig 17: Tapping Out Lever Lock Pin Using Brass Bar, Hammer & Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INNER SHIFT LEVER OIL SEAL
1. Using a screwdriver, pry out the oil seal from the front case.
  
  Fig 18: Prying Out Oil Seal From Front Case Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT OIL SEAL
1. Using SST and a hammer, tap out the oil seal.
  SST 09316-60011 (09316-00011)
  
  Fig 19: Tapping Out Oil Seal Using SST & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL RECEIVER
1. Remove the bolt and oil receiver from the front case.
  
  Fig 20: Removing Bolt & Oil Receiver From Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING RACE
1. Using SST, remove the bearing race (for the idler gear).
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010), 09950-60010 (09951-00320)
  
  Fig 21: Removing Bearing Race (For Idler Gear) Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap out the bearing race (for the output shaft) from the front case.
  
  Fig 22: Tapping Out Bearing Race (For Output Shaft) From Front Case Using Brass Bar & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002