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Transfer Assembly: Disassembly

  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. Remove the 4 transfer and transaxle setting stud bolts.
    Fig 1: Locating Transfer And Transaxle Setting Stud Bolts
    G06025210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 2 TRANSFER CASE PLUG 
    1. Remove the No. 2 transfer case plug.
    2. Remove the gasket from the No. 2 transfer case plug.
    Fig 2: Locating No. 2 Transfer Case Plug
    G06025211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE NO. 1 TRANSFER CASE PLUG 
    1. Remove the No. 1 transfer case plug.
    2. Remove the gasket from the No. 1 transfer case plug.
    Fig 3: Locating No. 1 Transfer Case Plug
    G06025212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSFER DRAIN PLUG 
    1. Remove the transfer drain plug.
    2. Remove the gasket from the transfer drain plug.
    Fig 4: Locating Transfer Drain Plug
    G06025213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSFER CASE BREATHER PLUG 
    1. Using a screwdriver, remove the transfer case breather plug.
    Fig 5: Locating Transfer Case Breather Plug
    G05241020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 1 TRANSFER CASE COVER 
    1. Remove the 8 bolts.
      Fig 6: Locating No. 1 Transfer Case Cover Bolts
      G06025215Courtesy 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: Place the brass bar on the rib protruding from the case.
    Fig 7: Removing No. 1 Transfer Case Cover
    G06025216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE BREATHER OIL DEFLECTOR 
    1. Remove the bolt and breather oil deflector.
    Fig 8: Locating Bolt And Breather Oil Deflector
    G06025217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSFER DYNAMIC DAMPER 
    1. Remove the 3 bolts and transfer dynamic damper from the transfer extension housing sub-assembly.
    Fig 9: Locating Transfer Dynamic Damper Bolts
    G06025218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 4 transfer case straight pins from the transfer case.
    Fig 10: Locating Transfer Case Straight Pins
    G06025219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. SECURE TRANSFER ASSEMBLY 
    1. Attach the transfer assembly to the overhaul attachment.
  11. 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 11: Removing Transfer Extension Housing Dust Deflector
    G06025220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE TRANSFER CASE REAR OIL SEAL 
    1. Using SST, remove the transfer case rear oil seal from the transfer extension housing sub-assembly.

      SST 09308-00010 

      NOTE: Be careful not to damage the oil seal contact surface or the inside surface of the oil seal.
      Fig 12: Removing Transfer Case Rear Oil Seal
      G06025221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 4 bolts.
      Fig 13: Locating Transfer Extension Housing Bolts
      G06025222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case.
      3. Fig 14: Removing Transfer Extension Housing Sub-Assembly
      G06025223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT PRELOAD  (See INSPECTION )
  15. INSPECT RING GEAR BACKLASH  (See INSPECTION )
  16. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION  (See INSPECTION )
  17. REMOVE TRANSFER CASE FRONT OIL SEAL 
    1. Using SST, remove the transfer case front oil seal from the transfer case.

    SST 09308-00010 

    NOTE: Do not damage the oil seal contact surface on the case.
    Fig 15: Removing Transfer Case Front Oil Seal
    G06025224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE TRANSFER CASE FRONT OIL SEAL (for RH Side) 
    1. Using SST, remove the transfer case front oil seal from the transfer case.

      SST 09308-00010 

      NOTE: Do not damage the oil seal contact surface on the case.
      Fig 16: Removing Transfer Case Front Oil Seal
      G06025225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE BEARING CAP 
    1. Remove the 2 bolts and bearing cap.
    Fig 17: Locating Bearing Cap And Bolts
    G06025226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER 
    1. Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer.

    Text in Illustration 

    ILLUSTRATION LEGEND

    *1 Screwdriver
    *2 Piece of Cloth
    *3 Spacer

    SST 09504-22011 

    NOTE: Do not damage the transfer case.
    Fig 18: Removing No. 1 Transfer Output Shaft Spacer
    G06025227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER 
  22. REMOVE TRANSFER RING GEAR MOUNTING CASE 
    1. Remove the transfer ring gear mounting case from the transfer case.
    Fig 19: Identifying Transfer Ring Gear Mounting Case
    G06025228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE DRIVEN PINION 
    1. Using SST and a hammer, unstake the gear nut.

      SST 09930-00010 HINT: 

      • Use SST with the flat side facing outward.
      • Do not machine the tip of SST with a grinder, etc.
      Fig 20: Unstaking Gear Nut
      G06025229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the gear nut.

      Text in Illustration 

      ILLUSTRATION LEGEND

      *1 Turn
      *2 Hold

      SST 09326-20011, 09556-16030 

      Fig 21: Removing Gear Nut
      G06025230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a press, press out the driven pinion, transfer driven pinion rear bearing (inner race) and transfer pinion bearing spacer.
    NOTE:
    • Place a piece of cloth under the transfer case to prevent the driven pinion from dropping out of the bearing.
    • Use wooden blocks or similar objects under the case to keep it level.
    Fig 22: Pressing Out The Driven Pinion, Transfer Driven Pinion Rear Bearing (Inner Race) And Transfer Pinion Bearing Spacer
    G06025231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST and a press, press out the front transfer driven pinion bearing (inner race).

      SST 09950-00020 

      Fig 23: Pressing Out Front Transfer Driven Pinion Bearing
      G06025232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the driven pinion front bearing (outer race) to remove it from the case.
      3. Fig 24: Removing Driven Pinion Front Bearing
      G06025233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSFER OUTPUT SHAFT WASHER 
  26. REMOVE RING GEAR MOUNTING CASE BEARING 
    1. Remove the ring gear mounting case bearing (outer race) from the transfer ring gear mounting case.
    2. Using SST, remove the ring gear mounting case bearing (inner race) from the transfer ring gear mounting case.

      Text in Illustration 

      ILLUSTRATION LEGEND

      *1 Turn
      *2 Hold

      SST 09950-40011 (09951 -04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00440) 

      Fig 25: Removing Ring Gear Mounting Case Bearing
      G06025234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Use SST (09953-04020) after applying grease to its threads and tip.
    3. Using SST, remove the ring gear mounting (inner race) from the transfer ring gear mounting case.

      Text in Illustration 

      Fig 26: Removing Ring Gear Mounting (Inner Race)
      G06025235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      ILLUSTRATION LEGEND

      *1 Turn
      *2 Hold

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00400) 

      NOTE: Use SST (09953-04020) after applying grease to its threads and tip.
    4. Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the ring gear mounting case bearing (outer race) to remove it from the transfer case.
    5. Remove the ring gear mounting case plate washer.
      6. Fig 27: Locating Ring Gear Bolts
      G06025236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSPECT RUNOUT OF RING GEAR  (See INSPECTION )
  28. REMOVE RING GEAR 
    1. Put matchmarks on the transfer ring gear mounting case and ring gear.

      Text in Illustration 

      Fig 28: Identifying Matchmarks On Transfer Ring Gear Mounting Case And Ring Gear
      G06025237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      ILLUSTRATION LEGEND

      *1 Matchmark
    2. Remove the 10 bolts.
      NOTE: Confirm whether the bolts are precoated or uncoated as the tightening torque is different for each type.
    3. Using a plastic hammer, tap on the ring gear to separate it from the transfer ring gear mounting case.
    NOTE: Do not damage the ring gear teeth.
    Fig 29: Tapping On Ring Gear
    G06025238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSPECT TRANSFER RING GEAR MOUNTING CASE  (See INSPECTION )
  30. REMOVE TRANSFER DRIVEN PINION REAR BEARING 
    1. Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the transfer driven pinion rear bearing (outer race) to remove it from the transfer case.
    Fig 30: Removing Transfer Driven Pinion Rear Bearing
    G06025239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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