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Transfer Assembly: Reassembly

  1. CHECK NO. 2 SHIFT FORK AND CLUTCH SLEEVE CLEARANCE 
    1. Using a feeler gauge, measure the clearance between the No. 2 shift fork and clutch sleeve.

      Standard clearance: 0.10 to 0.40 mm (0.0039 to 0.0157 in.) 

      Maximum clearance: 0.40 mm (0.0157 in.) 

      If the clearance is greater than the maximum, replace the No. 2 shift fork or clutch sleeve.

      Fig 1: Measuring Clearance Between No. 2 Shift Fork & Clutch Sleeve Using Feeler Gauge
      G04436987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL BEARING RACE (OUTPUT SHAFT) 
    1. Using SST and a press, press in the bearing race to the front case.

      SST 09316-60011 (09316-00011, 09316-00031), 09950-60020 (09951-00890) 

      Fig 2: Pressing In Bearing Race (Output Shaft) To Front Case Using SST & Press
      G04436988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL BEARING RACE (IDLER GEAR) 
    1. Using SST and a press, press in the bearing race to the front case.

      SST 09316-60011 (09316-00031, 09316-00011), 09950-60020 (09951-00890) 

      Fig 3: Pressing In Bearing Race To Front Case Using SST & Press
      G04436989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL OIL RECEIVER 
    1. Install the oil receiver to the front case with the bolt.

      Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Fig 4: Installing Oil Receiver To Front Case With Bolt
      G04436990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL INPUT SHAFT OIL SEAL 
    1. Apply MP grease to the lip of a new oil seal.
    2. Using SST and a hammer, tap in the oil seal to the front case.

      SST 09316-60011 (09316-00011, 09316-00031) 

      Fig 5: Tapping Input Shaft Oil Seal To Front Case Using SST & Hammer
      G04436991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL INNER SHIFT LEVER OIL SEAL 
    1. Apply MP grease to the lip of a new oil seal.
    2. Using SST and a hammer, tap in the oil seal to the front case.

      SST 09950-60010 (09951-00270), 09950-70010 (09951-07150) 

      Fig 6: Tapping Inner Shift Lever Oil Seal To Front Case Using SST & Hammer
      G04436992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL OUTER SHIFT LEVER AND INNER SHIFT LEVER 
    1. Install the inner shift lever, washer and outer shift lever to the front case.
    2. Using a pin punch, hammer and socket wrench, tap in the lever lock pin.
    3. Install the washer and nut to the outer shift lever.

      Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Fig 7: Tapping In Lever Lock Pin Using Pin Punch, Hammer & Socket Wrench
      G04436993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. ASSEMBLE NO. 1 SHIFT FORK AND NO. 1 SHIFT FORK SHAFT 
    1. Assemble the No. 1 shift fork and No. 1 shift fork shaft.
    2. Using a pin punch and hammer, tap in the slotted spring pin.
      Fig 8: Tapping In Slotted Spring Pin Using Pin Punch & Hammer
      G04436994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, NO. 1 SHIFT FORK AND NO. 1 SHIFT FORK SHAFT 
    NOTE: Set the shift inner lever into the fork head part of the No. 1 shift fork securely.
  10. INSTALL INPUT SHAFT SUB-ASSEMBLY 
  11. INSTALL BEARING RACE 
    1. Install the 2 bearing races to the rear case.
      Fig 9: Installing Idler Gear Assembly With Center Differential Assembly, No. 1 Shift Fork & No. 1 Shift Fork Shaft
      G04436995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. ASSEMBLE FRONT CASE AND REAR CASE 
    1. Apply FIPG to the front case.

      FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 

    2. Assemble the front case and rear case.
      Fig 10: Applying FIPG To Front Case
      G04436996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply liquid sealer to the "A" bolt threads.

      Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    4. Install the 8 bolts.

      Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 

      Fig 11: Applying Liquid Sealer To "A" Bolt Threads
      G04436997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a snap ring expander, install the snap ring to the rear case.
      Fig 12: Installing Snap Ring To Rear Case Using Snap Ring Expander
      G04436998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL CASE COVER 
    1. Apply FIPG to the rear case.

      FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 

    2. Install the case cover.
      Fig 13: Applying FIPG To Rear Case
      G04436999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply liquid sealer to the bolt threads.

      Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    4. Install the 5 bolts.

      Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 

      Fig 14: Installing 5 Bolts
      G04437000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL OIL STRAINER ASSEMBLY 
    1. Install the oil strainer to the rear case with the 2 bolts.

      Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 

      Fig 15: Installing Oil Strainer To Rear Case
      G04437001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. SELECT ADJUSTING SHIM (REAR IDLER GEAR TAPER ROLLER BEARING) 
    1. Using a vernier caliper, measure dimension "A".
    2. Lightly hold down the outer bearing race in the thrust direction to eliminate any looseness before making the measurement.
      Fig 16: Measuring Dimension "A" Using Vernier Caliper
      G04437002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a steel straight edge and feeler gauge, measure the clearance of dimension "B".
    4. Calculate the required thickness of the adjusting shim.

      Standard thickness: Dimension "A" + Dimension "B" + (0.022 to 0.049 mm, (0.0009 to 0.0019 in.)) 

      Fig 17: Measuring Clearance Of Dimension "B" Using Steel Straight Edge & Feeler Gauge
      G04437003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. From STANDARD SNAP RING THICKNESS  , select a shim so that its thickness is within the range of the calculation.

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      2 0.30 (0.0118) 8 3.20 (0.1260)
      3 0.45 (0.0177) 9 3.40 (0.1339)
      4 2.40 (0.0945) 10 3.60 (0.1417)
      5 2.60 (0.1024) 11 3.80 (0.1496)
      6 2.80 (0.1102) 12 4.00 (0.1575)
      7 3.00 (0.1181) 13 0.55 (0.0216)
  16. SELECT ADJUSTING SHIM (OUTPUT SHAFT TAPER ROLLER BEARING) 
    1. Using a steel straight edge and feeler gauge, measure the clearance of dimension "C".
    2. Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
      Fig 18: Measuring Clearance Of Dimension "C" Using Steel Straight Edge & Feeler Gauge
      G04437004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a steel straight edge and vernier caliper with depth gauge, measure dimension "D".
    4. Dimension "D" is the straightedge thickness (Dimension "F") subtracted from dimension "E".

      Dimension "D": Dimension "E" - Dimension "F" 

    5. Using a steel straight edge and vernier caliper with depth gauge, measure dimension "G".
      Fig 19: Measuring Dimension "D" Using Steel Straight Edge & Vernier Caliper With Depth Gauge
      G04437005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Dimension "G" is the straight edge thickness (Dimension "F") subtracted from Dimension "H".

      Dimension "G": Dimension "H" - Dimension "F" 

    7. Calculate the require thickness of the adjusting shim.

      Thickness: Dimension "G" - (Dimension "D" - Dimension "C") + (0.014 to 0.039 mm, (0.0006 to 0.0015 in.)) 

      Fig 20: Measuring Dimension "G" Using Steel Straight Edge & Vernier Caliper
      G04437006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. From STANDARD SNAP RING THICKNESS  , select a shim so that its thickness is within the range of the calculation.

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      B 0.30 (0.0118) H 1.80 (0.0709)
      C 0.45 (0.0177) J 2.00 (0.0787)
      D 1.00 (0.0394) K 2.20 (0.0866)
      E 1.020 (0.0472) L 2.40 (0.0945)
      F 1.40 (0.0551) M 2.60 (0.1024)
      G 1.60 (0.0630) N 0.56 (0.0216)
  17. INSTALL REAR TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Apply FIPG to the extension housing.

      FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 21: Applying FIPG To Extension Housing
      G04437007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the extension housing with the 9 bolts.

      Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 

      Fig 22: Installing Extension Housing With 9 Bolts
      G04437008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. ASSEMBLE NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK 
    1. Install the No. 2 shift fork to the No. 2 shift fork shaft.
    2. Install the 3 snap rings to the No. 2 shift fork shaft.
  19. INSTALL CLUTCH SLEEVE WITH NO. 2 SHIFT FORK SHAFT AND NO. 2 SIFT FORK 

    HINT:

    Make sure to install the clutch sleeve in the correct direction.

    Fig 23: Assembling No. 2 Shift Fork Shaft & No. 2 Shift Fork
    G04437009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FRONT TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Apply FIPG to the extension housing.

      FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 24: Applying FIPG To Extension Housing
      G04437010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the extension housing with the 6 bolts.

      Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 

      HINT:

      Set the clutch sleeve in differential lock condition.

  21. INSTALL TRANSFER INDICATOR SWITCH 
    1. Install the 3 indicator switches with 3 new gaskets.

      Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 

      Fig 25: Installing Extension Housing With 6 Bolts
      G04437011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL BALL 
  23. INSTALL SPRING 
  24. INSTALL SCREW PLUG 
    1. Apply liquid sealer to the screw plug threads.

      Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    2. Using a T40 "torx" socket, install the screw plug.

      Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) 

      Fig 26: Installing Screw Plug
      G04437012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL OUTPUT GEAR 
    1. Apply gear oil to the output gear.
    2. Install the output gear to the front case.
      NOTE: Do not turn the output gear.
      Fig 27: Installing Output Gear To Front Case
      G04437013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL MOTOR ACTUATOR 
    1. Apply FIPG to the motor actuator.

      FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 28: Applying FIPG To Motor Actuator
      G04437014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Set the motor actuator in differential lock condition.

      Fig 29: Setting Motor Actuator In Differential Lock Condition
      G04437015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the motor actuator with the 4 bolts.

      Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 

  27. INSTALL VEHICLE SPEED SENSOR DRIVEN GEAR 
    1. Install the driven gear with the bolt.

      Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) 

  28. INSTALL BREATHER HOSE 
    Fig 30: Installing Motor Actuator With 4 Bolts
    G04437016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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