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Transfer Assembly: Reassembly

  1. INSTALL BREATHER OIL DEFLECTOR 
    1. Install the deflector with the 2 bolts.

      Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) 

  2. INSTALL RING GEAR MOUNTING CASE PLATE WASHER 
    1. Install a new washer to the transfer case.

      HINT:

      Install a washer of the same thickness as before.

      Fig 1: Installing Deflector With 2 Bolts
      G04488803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TRANSFER RING GEAR MOUNTING CASE NO. 2 WASHER 
    1. Install a new washer to the cover.

      HINT:

      Install a washer of the same thickness as before.

  4. INSTALL TRANSFER RING GEAR MOUNTING CASE 
    1. Using SST and a press, press in the mounting case to the ring gear.

      SST 09316-12010, 09950-60010 (09951-00560) 

      Fig 2: Installing Transfer Ring Gear Mounting Case
      G04488804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL SHAFT SNAP RING 
    1. Using SST, install a new snap ring.
      Fig 3: Installing New Snap Ring Using SST
      G04488805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL RING GEAR MOUNTING CASE BEARING (for RH side) 
    1. Using SST and a press, press in the bearing (race) to the cover.

      SST 09950-60020 (09951-00750, 09952-06010), 09950-70010 (09951-07150) 

      Fig 4: Installing Ring Gear Mounting Case Bearing (For RH Side)
      G04488806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press in the bearing to the mounting case.

      SST 09336-16010, 09950-60010 (09951-00400) 

    3. Apply gear oil to the bearing.
      Fig 5: Pressing Bearing In To Mounting Case
      G04488807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL RING GEAR MOUNTING CASE BEARING (for LH side) 
    1. Using SST and a press, press in the bearing (race) to the case.

      SST 09950-60010 (09951-00540, 09951-00620, 09952-06010), 09950-70010 (09951-07150) 

      Fig 6: Installing Ring Gear Mounting Case Bearing (For LH Side)
      G04488808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press in the bearing to the mounting case.

      SST 09336-16010, 09950-60010 (09951-00560) 

    3. Apply gear oil to the mounting case bearing.
      Fig 7: Pressing Bearing In To Mounting Case
      G04488809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL TRANSFER OUTPUT WASHER 
    1. Install the washer to the driven pinion.
      Fig 8: Installing Washer To Driven Pinion
      G04488810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST and a press, press in the bearing to the driven pinion.

      SST 09950-60010 (09951-00440), 09950-60020 (09951-00750), 09950-70010 (09951-07150) 

      Fig 9: Installing Transfer Driven Pinion Front Bearing
      G04488811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL TRANSFER OUTPUT REAR SHAFT DUST DEFLECTOR 
    1. Using SST and a press, press in the dust deflector to the out put shaft.

      SST 09316-12010 

      Fig 10: Installing Transfer Output Rear Shaft Dust Deflector
      G04488812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL TRANSFER OUTPUT REAR SHAFT SUB-ASSEMBLY 
    1. Using SST and a press, press in the output rear shaft to the driven pinion.

      SST 09316-12010 

      Fig 11: Installing Transfer Output Rear Shaft Sub-Assembly
      G04488813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new nut to the output shaft.

      Torque: 360 N*m (3700 kgf*cm, 266 ft.*lbf) 

      Fig 12: Installing New Nut To Output Shaft
      G04488814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL TRANSFER SHAFT 
    1. Install a new O-ring to the driven pinion.
      Fig 13: Installing New O-Ring To Driven Pinion
      G04488815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the driven pinion to the case with the 5 bolts.

      Torque: 38 N*m (390 kgf*cm, 28 ft.*lbf) 

      Fig 14: Installing Driven Pinion To Case With 5 Bolts
      G04488816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT DRIVEN PINION PRELOAD 
    1. Using a torque wrench, measure the preload.

      Standard preload (turning): 0.17 to 1.86 N*m (1.7 to 19.0 kgf*cm, 1.5 to 16.5 in.*lbf) 

      Fig 15: Inspecting Driven Pinion Preload
      G04488817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL TRANSFER RING GEAR 
    1. Coat 3 or 4 teeth at the 4 different positions on the ring gear with Prussian blue.
      Fig 16: Installing Transfer Ring Gear
      G04488818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the mounting case to the transfer case.
      Fig 17: Installing Mounting Case To Transfer Case
      G04488819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL NO. 1 TRANSFER CASE COVER 
    1. Install the transfer cover with the 8 bolts.

      Torque: 47 N*m (480 kgf*cm, 35 ft.*lbf) 

      Fig 18: Installing Transfer Cover With 8 Bolts
      G04488820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. ADJUST RING GEAR BACKLASH 
    1. Using a dial indicator, measure the backlash of the ring gear at 3 positions at least.

      Standard backlash: 0.10 to 0.20 mm (0.0039 to 0.0079 in.) 

      HINT:

      The measure values should be used as reference when selecting washer, so take a note of the values. If the backlash is not within the specification, replace the washer on the ring gear side with one of a different thickness using the following procedure.

      Fig 19: Measuring Backlash Of Ring Gear Using Dial Indicator
      G04488821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard washer thickness 

      STANDARD WASHER THICKNESS

      Mark Thickness Mark Thickness
      A0 1.97 mm (0.0776 in.) C0 2.37 mm (0.0933 in.)
      A1 1.99 mm (0.0783 in.) C1 2.39 mm (0.0941 in.)
      A2 2.01 mm (0.0791 in.) C2 2.41 mm (0.0949 in.)
      A3 2.03 mm (0.0799 in.) C3 2.43 mm (0.957 in.)
      A4 2.05 mm (0.0807 in.) C4 2.45 mm (0.0965 in.)
      A5 2.07 mm (0.0815 in.) C5 2.47 mm (0.0972 in.)
      A6 2.09 mm (0.0823 in.) C6 2.49 mm (0.098 in.)
      A7 2.11 mm (0.0831 in.) C7 2.51 mm (0.0988 in.)
      A8 2.13 mm (0.0839 in.) C8 2.53 mm (0.0996 in.)
      A9 2.15 mm (0.0846 in.) C9 2.55 mm (0.1004 in.)
      B0 2.17 mm (0.0854 in.) D0 2.57 mm (0.1012 in.)
      B1 2.19 mm (0.0862 in.) D1 2.59 mm (0.102 in.)
      B2 2.21 mm (0.087 in.) D2 2.61 mm (0.1028 in.)
      B3 2.23 mm (0.0878 in.) D3 2.63 mm (0.1035 in.)
      B4 2.25 mm (0.0886 in.) D4 2.65 mm (0.1043 in.)
      B5 2.27 mm (0.0894 in.) D5 2.67 mm (0.1051 in.)
      B6 2.29 mm (0.0902 in.) D6 2.39 mm (0.0941 in.)
      B7 2.31 mm (0.0909 in.) D7 2.71 mm (0.1067 in.)
      B8 2.33 mm (0.0917 in.) D8 2.73 mm (0.1075 in.)
      B9 2.35 mm (0.0925 in.) D9 2.75 mm (0.1083 in.)
  17. ADJUST TOTAL PRELOAD 
    1. Using a torque wrench, measure the total preload.

      Driven pinion preload: 0.28 to 0.79 N*m (2.86 to 8.06 kgf*cm, 2.48 to 7.0 in.*lbf) 

      HINT:

      Turn the driven pinion counterclockwise and clockwise several times.

      If the preload is not as standard, select a proper washer again.

      Fig 20: Measuring Total Preload Using Torque Wrench
      G04488822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard washer thickness 

      STANDARD WASHER THICKNESS

      Mark Thickness Mark Thickness
      A0 1.18 mm (0.0465 in.) C2 1.62 mm (0.0638 in.)
      A1 1.20 mm (0.0472 in.) C3 1.64 mm (0.0646 in.)
      A2 1.22 mm (0.048 in.) C4 1.66 mm (0.0654 in.)
      A3 1.24 mm (0.0488 in.) C5 1.68 mm (0.0661 in.)
      A4 1.26 mm (0.0496 in.) C6 1.70 mm (0.067 in.)
      A5 1.28 mm (0.0504 in.) C7 1.72 mm (0.0677 in.)
      A6 1.30 mm (0.0512 in.) C8 1.74 mm (0.0685 in.)
      A7 1.32 mm (0.052 in.) C9 1.76 mm (0.0693 in.)
      A8 1.34 mm (0.0528 in.) D0 1.78 mm (0.0701 in.)
      A9 1.36 mm (0.535 in.) D1 1.80 mm (0.0709 in.)
      B0 1.38 mm (0.0543 in.) D2 1.82 mm (0.0717 in.)
      B1 1.40 mm (0.0551 in.) D3 1.84 mm (0.0724 in.)
      B2 1.42 mm (0.0559 in.) D4 1.86 mm (0.0732 in.)
      B3 1.44 mm (0.0567 in.) D5 1.88 mm (0.074 in.)
      B4 1.46 mm (0.0575 in.) D6 1.90 mm (0.0748 in.)
      B5 1.48 mm (0.0583 in.) D7 1.92 mm (0.0756 in.)
      B6 1.50 mm (0.0591 in.) D8 1.94 mm (0.0764 in.)
      B7 1.52 mm (0.0598 in.) D9 1.96 mm (0.0772 in.)
      B8 1.54 mm (0.0606 in.) E0 1.98 mm (0.0781 in.)
      B9 1.56 mm (0.0614 in.) E1 2.00 mm (0.0787 in.)
      C0 1.58 mm (0.0622 in.) E2 2.02 mm (0.0795 in.)
      C1 1.60 mm (0.063 in.) - -
  18. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION 
    1. Rotate the ring gear several times.
    2. Peer into the service filler hole or remove the ring gear to check the tooth contact pattern.
      NOTE:
      • Check the tooth contact pattern at 4 or more positions around the circumference of the ring gear.
      • When replacing washers (backlash adjustment, preload adjustment or tooth contact adjustment), reapply Prussian blue.
      Fig 21: Inspecting Tooth Contact Between Ring Gear And Drive Pinion
      G04488823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      The Prussian blue pattern indicates the tooth contact points.

    3. If the teeth are not contacting properly, select a driven pinion bearing front (outer race) side washer from the chart and install the washer.
      NOTE: If a washer (for tooth contact adjustment) is replaced with one of a different thickness, the backlash will also change. Therefore, it is necessary to adjust the backlash.
    4. Perform the following procedures for face or flank contact
      1. Use the backlash adjustment washer (ring gear mounting case washer) to move and adjust the ring gear. (*1)
      2. Perform the ring gear and driven pinion tooth contact inspection again.

        HINT:

        If the tooth contact is incorrect, repeat step *1.

      3. Perform the ring gear and driven pinion backlash inspection. If the ring gear and driven pinion backlash is not within the standard range, replace the ring gear and driven pinion with new ones.
    5. Perform the following procedures for heel or toe contact.
      1. Select a transfer driven pinion bearing front (outer race) side washer (transfer output shaft washer) from the chart and install the washer.
        NOTE: Do not reuse a transfer pinion bearing spacer.

        Standard washer thickness 

        STANDARD WASHER THICKNESS

        Mark Thickness Mark Thickness
        01 1.02 mm (0.0402 in.) 15 1.30 mm (0.0512 in.)
        02 1.04 mm (0.0409 in.) 16 1.32 mm (0.0520 in.)
        03 1.06 mm (0.0417 in.) 17 1.34 mm (0.0528 in.)
        04 1.08 mm (0.0425 in.) 18 1.36 mm (0.0535 in.)
        05 1.10 mm (0.0433 in.) 19 1.38 mm (0.0543 in.)
        06 1.12 mm (0.0441 in.) 20 1.40 mm (0.0551 in.)
        07 1.14 mm (0.0449 in.) 21 1.42 mm (0.0559 in.)
        08 1.16 mm (0.0457 in.) 22 1.44 mm (0.0567 in.)
        09 1.18 mm (0.0465 in.) 23 1.46 mm (0.0575 in.)
        10 1.20 mm (0.0472 in.) 24 1.48 mm (0.0583 in.)
        11 1.22 mm (0.0480 in.) 25 1.50 mm (0.0591 in.)
        12 1.24 mm (0.0488 in.) 26 1.52 mm (0.0598 in.)
        13 1.26 mm (0.0496 in.) 27 1.54 mm (0.0606 in.)
        14 1.28 mm (0.0504 in.) 28 1.56 mm (0.0614 in.)
  19. COMPLETELY INSTALL TRANSFER SHAFT 
    1. Using a screwdriver and hammer, unstake the pinion gear nut.
    2. Install the 5 bolts with the transfer shaft to the case.

      Torque: 38 N*m (390 kgf*cm, 28 ft.*lbf) 

    3. Install the No. 1 transfer case cover.
      1. Using white gasoline, clean the contact surfaces of the housing and cover.
        Fig 22: Installing 5 Bolts With Transfer Shaft To Case
        G04488824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Apply seal packing to the cover as shown in the illustration.

        Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent 

        Fig 23: Applying Seal Packing To Cover
        G04488825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Install the 8 bolts with the cover to the case.

        Torque: 47 N*m (480 kgf*cm, 35 ft.*lbf) 

  20. INSTALL TRANSFER CASE OIL SEAL LH (See  REPLACEMENT  ) 
  21. INSTALL TRANSFER CASE OIL SEAL RH (See  REPLACEMENT  ) 
  22. INSTALL TRANSFER CASE STRAIGHT PIN 
    1. Using a plastic-faced hammer, install the straight pin as shown in the straight pin.
      Fig 24: Installing 8 Bolts With Cover To Case
      G04488826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 25: Installing Transfer Case Straight Pin
      G04488827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL TRANSFER CASE BREATHER PLUG 
    1. Using SST and a hammer, tap in a new breather plug.

      SST 09612-10093 (09612-10061) 

      Fig 26: Installing Transfer Case Breather Plug
      G04488828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL TRANSFER DRAIN PLUG 
    1. Install a new gasket and the plug to the transfer case.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

  25. INSTALL TRANSFER CASE NO. 1 PLUG 
    1. Install a new gasket and the plug to the transfer case.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

      Fig 27: Installing Transfer Case No. 1 Plug
      G04488829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL TRANSFER CASE NO. 2 PLUG 
    1. Install a new gasket and the plug to the transfer case.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

      Fig 28: Installing Transfer Case No. 2 Plug
      G04488830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. Apply sealer to stud bolts.
    2. Install the stud bolts.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

      HINT:

      Install the transfer side of the stud bolt to the case (see illustration below).

      Fig 29: Installing Transfer And Transaxle Setting Stud Bolt
      G04488831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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