Transfer Assembly: Reassembly

1. Using SST and a press, press the transfer driven pinion rear bearing (outer race) into the case.

   SST 09950-60010 (09951-00620), 09950-70010 (09951-07150) 

   NOTE: Keep the transfer case horizontal using wooden blocks, etc.
   Fig 1: Installing Transfer Driven Pinion Rear Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply gear oil to the transfer driven pinion rear bearing (outer race).

1. Install the transfer output shaft washer to the transfer case.

   HINT:

   Install the same washer as the one removed.

2. Apply gear oil to the transfer output shaft washer.

1. Apply gear oil to the inner surface of the transfer case.

   Text in Illustration 

   ILLUSTRATION LEGEND
   
   

   *1	Turn
   *2	Hold

2. Using SST, install the front transfer driven pinion bearing (outer race) to the transfer case.

   SST 09950-60010 (09951 -00610, 09951 -00620, 09951-00650), 09950-60020 (09951-00680) 

   Fig 2: Installing Front Transfer Driven Pinion Bearing (Outer Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press the driven pinion front bearing (inner race) into the driven pinion.

SST 09506-30012 

Fig 3: Pressing Driven Pinion Front Bearing (Inner Race)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the driven pinion to the transfer case.
   Fig 4: Installing Driven Pinion

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new transfer pinion bearing spacer and driven pinion rear bearing (inner race) to the driven pinion.

   HINT:

   Install the pinion bearing spacer with the larger inner diameter facing forward as shown in the illustration.

   Fig 5: Identifying Transfer Pinion Bearing Spacer And Driven Pinion Rear Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, install a new gear nut.

SST 09326-20011, 09556-16030 

Torque: without SST 

270 to 420 N*m (2751 to 4280 kgf*cm, 198 to 308 ft.*lbf) 

with SST 

254 to 396 N*m (2588 to 4035 kgf*cm, 186 to 291 ft.*lbf) 

HINT:

Using a torque wrench with a fulcrum length of 840 mm (33.07 in.).

Fig 6: Measuring Driven Pinion Preload

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a torque wrench, measure the driven pinion preload.

SST 09326-20011 

Fig 7: Measuring Driven Pinion Preload

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Preload (at Starting) 

HINT:

• Use a torque wrench with a fulcrum length of 130 mm (5.12 in.).
• If the preload is more than the specification, replace the pinion bearing spacer with a new one.
• If the preload is not sufficient, adjust the driven pinion by tightening the lock nut 5° to 10° and measuring the preload until the preload is within the specification.
• Even if the tightening torque of the gear nut exceeds the specified torque, if the preload is insufficient, loosen the gear nut once and apply rust preventive oil or hypoid gear oil to the gear nut and to the screw or bearing surface of the driven pinion. Then perform the procedure again. If the tightening torque is less than the specified torque, replace the pinon bearing spacer with a new one and adjust it.
• Do not loosen the pinion nut to reduce the preload.

1. Clean the contact surfaces of the ring gear and transfer ring gear mounting case.

   Text in Illustration 

   ILLUSTRATION LEGEND
   
   

   *1	Boiling Water

2. Heat the ring gear in boiling water.
3. Carefully remove the ring gear from the boiling water.
4. Align the matchmarks and quickly install the ring gear to the transfer ring gear mounting case.
5. for Seal Lock Bolt:
   Fig 8: Heating Ring Gear In Boiling Water

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Apply adhesive to 10 new bolts.

      Adhesive: 

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

6. After the moisture on the ring gear has completely evaporated, install the 10 bolts.

Text in Illustration 

Torque: for Seal Lock Bolt 

112 N*m (1142 kgf*cm, 82 ft.*lbf) 

except Seal Lock Bolt 

78 N*m (790 kgf*cm, 57 ft.*lbf) 

Fig 9: Locating Ring Gear Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, press the ring gear mounting case bearing (inner race) into the transfer ring gear mounting case.

   SST 09950-60010 (09951-00420) 

2. Install the ring gear mounting case bearing (outer race) to the transfer ring gear mounting case.
3. Apply gear oil to the ring gear mounting case bearing RH.
   Fig 10: Installing Ring Gear Mounting Case Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a press, press the ring gear mounting case bearing (inner race) into the transfer ring gear mounting case.

   SST 09223-00010,09726-40010 

5. Install the ring gear mounting case plate washer to the case.

   HINT:

   Use a new washer with the same thickness as the one removed when installing the bearing.

   Fig 11: Pressing Ring Gear Mounting Case Bearing (Inner Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST and a press, press the ring gear mounting case bearing (outer race) into the transfer case.

   SST 09950-60010 (09951 -00620), 09950-70010 (09951-07200) 

7. Apply gear oil to the ring gear mounting case bearing.

Fig 12: Pressing Ring Gear Mounting Case Bearing (Outer Race)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply gear oil to the transfer ring gear mounting case.
2. Install the transfer ring gear mounting case to the transfer case.

Fig 13: Identifying Transfer Ring Gear Mounting Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the cutout on the No. 1 transfer output shaft spacer with the transfer case hole to install it as shown in the illustration.

Text in Illustration 

Fig 14: Installing No. 1 Transfer Output Shaft Spacer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a brass bar and a hammer, install the No. 2 transfer ring gear mounting case washer.

HINT:

Install the No. 2 washer with the same thickness as the one removed.

Fig 15: Installing No. 2 Transfer Ring Gear Mounting Case Washer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the bearing cap with the 2 bolts.

   Torque: 63 N*m (644 kgf*cm, 47 ft.*lbf) 

   Fig 16: Locating Bearing Cap With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set a dial indicator perpendicular to a ring gear tooth tip. Secure the driven pinion in place and move the ring gear back and forth to measure the backlash.

   Backlash: 

   0.14 to 0.25 mm (0.00551 to 0.00984 in.) 

   NOTE: Check at least 3 positions on the circumference of the ring gear.
   Fig 17: Inspecting Ring Gear Backlash

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If the backlash is outside the specified range, select a ring gear mounting case washer from the table and install it to meet the specified range.

Text in Illustration 

Fig 18: Identifying Ring Gear Mounting Case Washer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Washer Thickness 

1. Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.
2. Turn the driven pinion to rotate the ring gear 10 times or more clockwise and 10 times or more counterclockwise.
3. Rotate the ring gear to inspect the tooth contact pattern.
   Fig 19: Applying Prussian Blue To Ring Gear Teeth

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 20: Identifying Tooth Contact Pattern

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. If the tooth contact pattern is not correct, select a new transfer output shaft washer that is thicker or thinner as necessary and recheck.

Text in Illustration 

Washer Thickness 

Fig 21: Identifying Transfer Output Shaft Washer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a torque wrench, measure the total preload.

   SST 09326-20011 

   Fig 22: Measuring Total Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Total Preload (at Starting) 

   PRELOAD SPECIFICATION
   
   

   Item	Preload
   New bearing (without SST)	0.48 to 0.70 N*m (5 to 7 kgf*cm, 5 to 6 in.*lbf) + Driven pinion preload
   New bearing (with SST)	0.35 to 0.50 N*m (4 to 5 kgf*cm, 4 to 4.4 in.*lbf) + Driven pinion preload
   Reused bearing (without SST)	0.35 to 0.53 N*m (4 to 5 kgf*cm, 4 to 4.6 in.*lbf) + Driven pinion preload
   Reused bearing (with SST)	0.25 to 0.38 N*m (3 to 3.8 kgf*cm, 3 to 3.3 In.*lbf) + Driven pinion preload

   HINT:

   • Use a torque wrench with a fulcrum length of 130 mm (5.12 in.).
   • Turn the driven pinion counterclockwise and clockwise several times.

   If the preload is outside the specified range, replace the No. 2 transfer ring gear mounting case washer with one that is thicker or thinner as necessary and recheck.

   Text in Illustration 

   ILLUSTRATION LEGEND
   
   

   *1	No. 2 Transfer Ring Gear Mounting Case Washer

   Fig 23: Identifying No. 2 Transfer Ring Gear Mounting Case Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Washer Thickness: mm (in.) 

   WASHER THICKNESS SPECIFICATION
   
   

   Mark	Thickness	Mark	Thickness
   G7	2.47 (0.0972)	M7	3.47 (0.1366)
   G8	2.49 (0.0980)	M8	3.49 (0.1374)
   G9	2.51 (0.0988)	M9	3.51 (0.1382)
   H0	2.53 (0.0996)	N0	3.53 (0.1390)
   H1	2.55 (0.1004)	N1	3.55 (0.1398)
   H2	2.57 (0.1012)	N2	3.57 (0.1406)
   H3	2.59 (0.1020)	N3	3.59 (0.1413)
   H4	2.61 (0.1028)	N4	3.61 (0.1421)
   H5	2.63 (0.1035)	N5	3.63 (0.1429)
   H6	2.65 (0.1043)	N6	3.65 (0.1437)
   H7	2.67 (0.1051)	N7	3.67 (0.1445)
   H8	2.69 (0.1059)	N8	3.69 (0.1453)
   H9	2.71 (0.1067)	N9	3.71 (0.1461)
   J0	2.73 (0.1075)	P0	3.73 (0.1469)
   J1	2.75 (0.1083)	P1	3.75 (0.1476)
   J2	2.77 (0.1091)	P2	3.77 (0.1484)
   J3	2.79 (0.1098)	P3	3.79 (0.1492)
   J4	2.81 (0.1106)	P4	3.81 (0.1500)
   J5	2.83 (0.1114)	P5	3.83 (0.1508)
   J6	2.85 (0.1122)	P6	3.85 (0.1516)
   J7	2.87 (0.1130)	P7	3.87 (0.1524)
   J8	2.89 (0.1138)	P8	3.89 (0.1531)
   J9	2.91 (0.1146)	P9	3.91 (0.1539)
   K0	2.93 (0.1154)	Q0	3.93 (0.1547)
   K1	2.95 (0.1161)	Q1	3.95 (0.1555)
   K2	2.97 (0.1169)	Q2	3.97 (0.1563)
   K3	2.99 (0.1177)	Q3	3.99 (0.1571)
   K4	3.01 (0.1185)	Q4	4.01 (0.1579)
   K5	3.03 (0.1193)	Q5	4.03 (0.1587)
   K6	3.05 (0.1201)	Q6	4.05 (0.1594)
   K7	3.07 (0.1209)	Q7	4.07 (0.1602)
   K8	3.09 (0.1217)	Q8	4.09 (0.1610)
   K9	3.11 (0.1224)	Q9	4.11 (0.1618)
   L0	3.13 (0.1232)	R0	4.13 (0.1626)
   L1	3.15 (0.1240)	R1	4.15 (0.1634)
   L2	3.17 (0.1248)	R2	4.17 (0.1642)
   L3	3.19 (0.1256)	R3	4.19 (0.1650)
   L4	3.21 (0.1264)	R4	4.21 (0.1657)
   L5	3.23 (0.1272)	R5	4.23 (0.1665)
   L6	3.25 (0.1280)	R6	4.25 (0.1673)
   L7	3.27 (0.1287)	R7	4.27 (0.1681)
   L8	3.29 (0.1295)	R8	4.29 (0.1689)
   L9	3.31 (0.1303)	R9	4.31 (0.1697)
   M0	3.33 (0.1311)	S0	4.33 (0.1705)
   M1	3.35 (0.1319)	S1	4.35 (0.1713)
   M2	3.37 (0.1327)	S2	4.37 (0.1720)
   M3	3.39 (0.1335)	S3	4.39 (0.1728)
   M4	3.41 (0.1343)	S4	4.41 (0.1736)
   M5	3.43 (0.1350)	S5	4.43 (0.1744)
   M6	3.45 (0.1358)	S6	4.45 (0.1752)

2. Using a chisel and a hammer, stake the gear nut.

Fig 24: Staking Gear Nut

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, drive a new transfer case front oil seal into the case until it reaches the position shown in the illustration.

   SST 09950-60010 (09951 -00350, 09951 -00580, 09952-06010), 09950-70010 (09951-07150) 

   Drive in depth: 

   33.5 to 34.5 mm (1.319 to 1.358 in.) 

   NOTE: Do not install the oil seal at an angle.
2. Apply a small amount of MP grease to the lip of the transfer case front oil seal.

Fig 25: Installing Transfer Case Front Oil Seal Into Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, drive a new transfer case front oil seal into the transfer case until it reaches the position in the illustration.

   SST 09608-10010, 09950-70010 (09951-07150) 

   Drive in depth: 

   9.5 to 10.5 mm (0.374 to 0.413 in.) 

2. Apply a small amount of MP grease to the lip of the transfer case front oil seal.

Fig 26: Installing Transfer Case Front Oil Seal Into Transfer Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, drive a new transfer case rear oil seal into the extension housing until it reaches the position shown in the illustration.

   SST 09325-20010 

   Drive in depth: 

   1.1 to 1.9 mm (0.0433 to 0.0748 in.) 

2. Apply a small amount of MP grease to the lip of the transfer case rear oil seal.

Fig 27: Installing Transfer Case Rear Oil Seal Into Extension Housing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, press in the extension housing dust deflector until it contacts the installation surface as shown in the illustration.

SST 09950-60020 (09951 -00810), 09950-70010 (09951-07150) 

Fig 28: Pressing In Extension Housing Dust Deflector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any FIPG material and be careful not to drop oil on the contact surfaces of the transfer extension housing sub-assembly and the transfer case.
2. Degrease the surfaces with a non-residue solvent.
3. Apply FIPG to the transfer extension housing sub-assembly.

   FIPG: 

   Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

   Fig 29: Applying Fipg To Transfer Extension Housing Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the transfer extension housing sub-assembly with the 4 bolts to the transfer case.

   Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

   NOTE: Assemble the transfer extension housing sub-assembly within 10 minutes after the FIPG application.
   Fig 30: Locating Transfer Extension Housing Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the transfer assembly from the overhaul attachment.

1. Using a plastic hammer, drive the 4 transfer case straight pins into the transfer case positions shown in the illustration.

Fig 31: Identifying Transfer Case Straight Pins Location

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Text in Illustration 

1. Install the transfer dynamic damper with the 3 bolts to the transfer extension housing sub-assembly.

   Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

Fig 32: Locating Transfer Dynamic Damper With Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, tap in a new breather plug.

   SST 09820-00031 

Fig 33: Tapping In Breather Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the breather oil deflector with the bolt.

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

Fig 34: Locating Breather Oil Deflector And Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove any FIPG material and be careful not to drop oil on the contact surfaces of the No. 1 transfer case cover and the transfer case.
2. Degrease the surfaces with a non-residue solvent.
3. Apply FIPG to the No. 1 transfer case cover.

   FIPG: 

   Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

   Fig 35: Applying FIPG To No. 1 Transfer Case Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the No. 1 transfer case cover with the 6 bolts.

   Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

   NOTE:

   • Wait for at least one hour after installing the No. 1 transfer case cover before adding transfer oil.
   • Assemble the No. 1 transfer case cover within 10 minutes after the FIPG application.
   Fig 36: Locating No. 1 Transfer Case Cover With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the No. 1 transfer case cover with the new 2 bolts.

   Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

Fig 37: Locating No. 1 Transfer Case Cover With Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket to the transfer drain plug.
2. Install the transfer drain plug to the transfer assembly.

   Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

Fig 38: Locating Transfer Drain Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket to the No. 1 transfer case plug.
2. Install the No. 1 transfer case plug to the transfer assembly.

   Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

Fig 39: Locating No. 1 Transfer Case Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket to the No. 2 transfer case plug.
2. Install the No. 2 transfer case plug to the transfer assembly.

   Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

Fig 40: Locating No. 2 Transfer Case Plug

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1. Install the new 4 transfer and transaxle setting stud bolts to the transfer case positions shown in the illustration.

   Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

HINT:

Install the shorter end of the stud bolts to the transfer.

Fig 41: Locating Transfer And Transaxle Setting Stud Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Text in Illustration