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Transfer Assembly: Disassembly: Disassembly

  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. Remove the 4 transfer and transaxle setting stud bolts.
      Fig 1: Identifying Transfer And Transaxle Setting Stud Bolts Location
      GTY252970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 2 TRANSFER CASE PLUG 
    1. Remove the No. 2 transfer case plug.
      Fig 2: Identifying No. 2 Transfer Case Plug Location
      GTY252449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the No. 2 transfer case plug.
  3. REMOVE NO. 1 TRANSFER CASE PLUG 
    1. Remove the No. 1 transfer case plug.
      Fig 3: Identifying No. 1 Transfer Case Plug Location
      GTY248820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the No. 1 transfer case plug.
  4. REMOVE TRANSFER DRAIN PLUG 
    1. Remove the transfer drain plug.
      Fig 4: Identifying Transfer Drain Plug Location
      GTY250283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the transfer drain plug.
  5. REMOVE TRANSFER CASE BREATHER PLUG 
    1. Using a hammer and chisel, slightly raise the transfer case breather plug.
      Fig 5: Identifying Transfer Case Breather Plug Location
      GTY138617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the transfer case breather plug.
  6. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Remove the 8 bolts.
      Fig 6: Identifying Transfer Case Cover Sub-Assembly Fasteners
      GTY302986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the transfer case cover.
      Fig 7: Removing Transfer Case Cover Using Brass Bar & Hammer
      GTY295590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Rib Protruding
      NOTE:

      Place the brass bar on the rib protruding from the case.

  7. REMOVE BREATHER OIL DEFLECTOR 
    1. Remove the bolt and breather oil deflector.
      Fig 8: Identifying Breather Oil Deflector Bolt Location
      GTY242674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 4 transfer case straight pins.
      Fig 9: Identifying Transfer Case Straight Pins Location
      GTY250451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. SECURE TRANSFER ASSEMBLY 
    1. Attach the transfer onto the overhaul attachment.
  10. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR 
    1. Using a plastic hammer, remove the transfer extension housing dust deflector.
      Fig 10: Removing Transfer Extension Housing Dust Deflector
      GTY227909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Perform this step only when replacing the transfer extension housing dust deflector or transfer extension housing.

  11. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing.
      Fig 11: Removing Transfer Extension Housing Type T Oil Seal At Transfer Extension Housing Using SST
      GTY305094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Extension Housing Type T Oil Seal
      • SST: 09308-00010 
      NOTE:

      Do not damage the oil seal contact surface on the extension housing.

  12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 4 bolts.
      Fig 12: Identifying Transfer Extension Housing Bolts
      GTY244696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the transfer extension housing.
      Fig 13: Removing Transfer Extension Housing Sub-Assembly
      GTY244697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSFER CASE OIL SEAL 
    1. Using SST, remove the transfer case oil seal from the transfer case.
      Fig 14: Removing Transfer Case Oil Seal At Transfer Case Using SST
      GTY302084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Case Oil Seal
      • SST: 09308-00010 
      NOTE:

      Do not damage the oil seal contact surface on the case.

  14. REMOVE TRANSFER CASE RH OIL SEAL 
    1. Using SST, remove the transfer case RH oil seal from the transfer case.
      Fig 15: Removing Transfer Case RH Oil Seal At Transfer Case Using SST
      GTY305026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Case RH Oil Seal
      • SST: 09308-00010 
      NOTE:

      Do not damage the oil seal contact surface on the case.

  15. INSPECT PRELOAD 
    1. Using SST and a torque wrench, measure the preload of the backlash between the transfer driven pinion and transfer ring gear.
      Fig 16: Measuring Total Preload
      GTY222410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09326-20011 

      Preload (at Starting)

      Item Preload
      with SST 0.3 to 0.6 N*m (3 to 6 kgf*cm, 3 to 5 in.*lbf)
      without SST 0.4 to 0.9 N*m (4 to 9 kgf*cm, 3 to 8 in.*lbf)

      HINT: 

      • The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).
      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.). Refer to PRECAUTION .
      • The "with SST" torque value is effective when SST is parallel to the torque wrench.
    2. Using SST and a torque wrench, measure the total preload.
      • SST: 09326-20011 

      Preload (at Starting)

      Item Preload
      with SST 0.25 to 0.38 N*m (2.6 to 3.8 kgf*cm, 2.3 to 3.3 in.*lbf)
      + driven pinion preload
      without SST 0.4 to 0.5 N*m (4 to 5 kgf*cm, 3 to 4 in.*lbf)
      + driven pinion preload

      HINT: 

      • The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).
      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.). Refer to PRECAUTION .
      • The "with SST" torque value is effective when SST is parallel to the torque wrench.
      • If necessary, disassemble and inspect the transfer assembly.
  16. INSPECT RING GEAR BACKLASH 
    1. Using a dial indicator, check the backlash of the transfer ring gear.
      Fig 17: Inspecting Ring Gear Backlash
      GTY226404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Backlash

      0.14 to 0.25 mm (0.00552 to 0.00984 in.)

      If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

      HINT: 

      Check at least 3 positions on the circumference of the ring gear.

  17. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION 
    1. Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.
      Fig 18: Applying Prussian Blue To Ring Gear Teeth
      GTY216211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Rotate the ring gear 10 times more.
    3. Rotate the ring gear to inspect the tooth contact pattern.
      Fig 19: Identifying Ring Gear Wear Pattern
      GTY296330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select a washer that will bring the driven pinion closer to the ring gear.
      *e Toe Contact *f Flank Contact
      *g Select a washer that will shift the driven pinion away from the ring gear. -f -
      • If the tooth contact pattern is not correct, select a new transfer output shaft washer that is thicker or thinner as necessary and recheck.
  18. REMOVE TRANSFER BEARING CAP 
    1. Remove the 2 bolts and transfer bearing cap.
      Fig 20: Locating Bearing Cap Bolts
      GTY214833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER 
    1. Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer.
      Fig 21: Removing No. 1 Transfer Output Shaft Spacer Using Screwdriver, Hammer & SST
      GTY300457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Screwdriver
      *2 Piece of Cloth
      *3 Spacer
      • SST: 09504-22011 
      NOTE:

      Do not damage the transfer case.

  20. REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER 
  21. REMOVE TRANSFER RING GEAR MOUNTING CASE 
    1. Remove the transfer ring gear mounting case.
      Fig 22: Identifying Transfer Ring Gear Mounting Case
      GTY242636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE TRANSFER DRIVEN PINION 
    1. Using SST and a hammer, unstake the transfer gear nut.
      Fig 23: Unstaking Gear Nut
      GTY242755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09930-00010 

      HINT: 

      • Use SST with the flat side facing outward.
      • Do not machine the tip of SST with a grinder, etc.
    2. Using SST, remove the transfer gear nut.
      Fig 24: Removing Transfer Gear Nut Using SST
      GTY301290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
      • SST: 09326-20011 
      • SST: 09556-16030 
    3. Using a press, press out the transfer driven pinion, transfer driven pinion rear bearing (inner race) and transfer pinion bearing spacer.
      Fig 25: Pressing Out Driven Pinion, Transfer Driven Pinion Rear Bearing (Inner Race) And Transfer Pinion Bearing Spacer
      GTY242640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  23. REMOVE TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST and a press, press out the transfer driven pinion front bearing (inner race).
      Fig 26: Identifying Transfer Driver Pinion Front Bearing & SST
      GTY307351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Driven Pinion Front Bearing (Inner Race)
      • SST: 09950-00020 
    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.
      Fig 27: Removing Driven Pinion Front Bearing
      GTY242641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. 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.
      Fig 28: Removing Driven Pinion Rear Bearing (Outer Race)
      GTY233817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSFER OUTPUT SHAFT WASHER 
    1. Remove the transfer output shaft washer.
  26. REMOVE RING GEAR MOUNTING CASE BEARING 
    1. Remove the ring gear mounting case bearing (RH side).
      Fig 29: Identifying Ring Gear Mounting Case Bearing And SST
      GTY292144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the ring gear mounting case bearing (outer race).
      2. Using SST, remove the ring gear mounting case bearing (inner race).
        TEXT IN ILLUSTRATION

        *1 Ring Gear Mounting Case Bearing (Inner Race)
        *a Turn
        *b Hold
        • SST: 09950-40011 
          • 09951-04010
          • 09952-04010
          • 09953-04020
          • 09954-04010
          • 09955-04061
          • 09957-04010
          • 09958-04011
        • SST: 09950-60010 
          • 09951-00440
        NOTE:

        Use SST (09953-04020) after applying grease to its threads and tip.

    2. Remove the ring gear mounting case bearing (LH side).
      Fig 30: Removing Ring Gear Mounting Case Bearing (Outer Race) LH
      GTY242647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. 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.
      2. Remove the ring gear mounting case plate washer.
      3. Using SST, remove the ring gear mounting case bearing (inner race).
        Fig 31: Identifying Ring Gear Mounting Case Bearing (Inner Race), Transfer Ring Gear Mounting Case And SST
        GTY292632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Ring Gear Mounting Case Bearing (Inner Race)
        *a Turn
        *b Hold
        • SST: 09950-40011 
          • 09951-04010
          • 09952-04010
          • 09953-04020
          • 09954-04010
          • 09955-04061
          • 09957-04010
          • 09958-04011
        • SST: 09950-60010 
          • 09951-00400
        NOTE:

        Use SST (09953-04020) after applying grease to its threads and tip.

  27. INSPECT RING GEAR RUNOUT 
    1. Place the transfer ring gear mounting case on the V-blocks.
      Fig 32: Checking Runout Of Ring Gear
      GTY232787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator, check the runout of the ring gear.

      Maximum runout

      0.06 mm (0.00236 in.)

      • If the runout is more than the maximum, replace the ring gear or transfer ring gear mounting case with a new one.
  28. REMOVE TRANSFER RING GEAR 
    1. Fix the transfer ring gear mounting case in a vise between aluminum plates.
      Fig 33: Identifying Transfer Ring Gear Fasteners & Matchmarks
      GTY302250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not overtighten the vise.

    2. Put matchmarks on the transfer ring gear mounting case and transfer ring gear.
      TEXT IN ILLUSTRATION

      *a Matchmark
    3. Remove the 12 bolts.
    4. Using a plastic hammer, tap on the transfer ring gear to separate it.
      Fig 34: Removing Transfer Ring Gear Using Plastic Hammer
      GTY299182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the transfer ring gear teeth.

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