Transfer ASSY: Overhaul

HINT:

COMPONENTS : TRANSFER ASSY 

1. DRAIN TRANSFER OIL 
2. REMOVE TRANSFER CASE LOWER PROTECTOR 
   1. Remove the 4 bolts and transfer case lower protector.
      Fig 1: Removing Transfer Case Lower Protector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE AUTOMATIC TRANSMISSION ASSY 
   1. 2UZ-FE : (See AUTOMATIC TRANSMISSION ASSY (FROM AUGUST, 2003) )
4. REMOVE TRANSFER ASSY 
   1. Remove the 8 bolts and 2 clamps from the transmission.
      Fig 2: Removing Transfer Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE HOSES 
   1. Remove a actuator motor breather hose.
      Fig 3: Removing Actuator Motor Breather Hose

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE SWITCH 
   1. Remove the indicator No.1 and No.2 switches, case No.1 plug and gaskets.
      Fig 4: Removing Indicator No.1 And No.2 Switches

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE TRANSFER GEAR SHIFT HEAD NO.2 
   1. Using a pin punch and hammer, remove the slotted pin from the gear shift head No.2.
      Fig 5: Removing Slotted Pin

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY 
   1. Remove the 5 bolts and the bearing retainer sub-assy.

   HINT:

   If necessary, tap the extension housing with a plastic hammer to remove it.

   Fig 6: Removing Bearing Retainer Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE TRANSFER COVER TYPE T OIL SEAL 
   1. Using a screwdriver and hammer, remove the oil seal from the bearing retainer sub-assy.
      Fig 7: Removing Oil Seal

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE TRANSFER CASE COVER SUB-ASSY 
    1. Remove the 4 bolts and case cover sub-assy.
11. REMOVE BREATHER OIL DEFLECTOR 
    Fig 8: Removing Breather Oil Deflector

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSY 
    1. Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut. (front)
    2. Using SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut. (front)
       1. SST 09330-00021
    3. Using SST, remove the output shaft companion flange sub-assy. (front)
       1. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
    Fig 9: Removing Output Shaft Companion Flange Sub-Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using a screwdriver and hammer, remove the oil seal from the output shaft companion flange sub-assy. (front)
14. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSY 
    1. Remove the rear output shaft companion flange sub-assy in the same way as the front output shaft companion flange sub-assy. (rear)
       1. SST 09330-00021, 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
15. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using a screwdriver and hammer, remove the oil seal from the rear output shaft companion flange sub-assy. (rear)
16. REMOVE EXTENSION HOUSING ASSY 
    1. Remove the 5 bolts and extension housing assy.

    HINT:

    If necessary, tap the extension housing assy rear with a plastic hammer to remove it.

17. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using a screwdriver and hammer, remove the oil seal.
       Fig 10: Removing Oil Seal

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE TRANSFER OUTPUT WASHER 
    1. Remove the 2 output washer and collar.
       Fig 11: Removing Output Washer And Collar

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE TRANSFER CASE REAR 
    1. Remove the 12 bolts and 2 clamps.
    2. Remove the transfer case rear.

    HINT:

    If necessary, tap the transfer case rear with a plastic hammer to remove it.

    Fig 12: Removing Transfer Case Rear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE TRANSFER GEAR SHIFT FORK NO.2 W/TRANSFER HIGH AND LOW CLUTCH SLEEVE 
    1. Using a hexagon wrench, remove the plug No.1.
    2. Using a magnetic finger, remove the spring and ball from the hole.
       Fig 13: Removing Spring And Ball

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a pin punch and hammer, drive out the slotted spring pin.
    4. Remove the gear shift fork No.2 and high and low shift fork shaft.
    5. Remove the high and low clutch sleeve.
21. REMOVE CTR DIFFERENTIAL LOCK FORK SUB-ASSY W/FRONT DRIVE CLUTCH SLEEVE 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.
       Fig 14: Removing Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, CTR differential lock fork sub-assy and front drive clutch sleeve.
       Fig 15: Removing Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. REMOVE REAR OUTPUT SHAFT SUB-ASSY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSY 
    1. Using a snap ring expander, remove the snap ring.
    2. Mount the transfer case rear in a vise.
       Fig 16: Removing Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, carefully tap the transfer case rear, and remove the rear output shaft sub-assy together with front drive chain and driven sprocket sub-assy.
       Fig 17: Removing Rear Output Shaft Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the rear output shaft sub-assy, front drive chain and driven sprocket sub-assy.
       Fig 18: Removing Rear Output Shaft Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    1. Using a press, remove the driven sprocket bearing.
       Fig 19: Removing Driven Sprocket Bearing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING 
    1. Using SST, a press and steel bar, remove the transfer input gear radial ball bearing.
       1. SST 09555-55010
       Fig 20: Removing Transfer Input Gear Radial Ball Bearing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. REMOVE TRANSFER SHIFT ACTUATOR ASSY 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.
       Fig 21: Removing Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and transfer shift actuator assy.
       Fig 22: Removing Transfer Shift Actuator Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. REMOVE TRANSFER CASE NO.1 PLUG 
    1. Remove the transfer case plug No.1 (filler plug) and gasket.
27. REMOVE TRANSFER CASE NO.1 PLUG 
    1. Remove the transfer case plug No.1 (drain plug) and gasket.
28. REMOVE TRANSFER OIL SEPARATOR SUB-ASSY 
    1. Remove the 3 bolts and oil separator sub-assy.
29. REMOVE TRANSFER CASE MAGNET 
    Fig 23: Removing Transfer Case Magnet

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. REMOVE TRANSFER OIL PUMP BODY SUB-ASSY 
    1. Remove the 3 bolts and oil pump body sub-assy.
       Fig 24: Removing Oil Pump Body Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. REMOVE TRANSFER OIL PUMP BODY O-RING 
    1. Using a screwdriver, remove the oil pump body O-ring.
       Fig 25: Removing Oil Pump Body O-Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. REMOVE TRANSFER OIL PUMP GEAR 
    Fig 26: Removing Transfer Oil Pump Gear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. REMOVE LOW PLANETARY GEAR ASSY W/INPUT SHAFT SUB-ASSY 
    1. Using a snap ring expander, remove the snap ring.
       Fig 27: Removing Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the low planetary gear assy and input shaft sub-assy.
       Fig 28: Removing Low Planetary Gear Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
34. REMOVE TRANSFER OUTPUT SHAFT SPACER 
35. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
    Fig 29: Removing Transfer Output Shaft Front Needle Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
36. REMOVE TRANSFER CASE OIL SEAL 
    1. Using a screwdriver and hammer, remove the transfer case oil seal (No.1).
    2. Using a screwdriver and hammer, remove the transfer case oil seal (No.2).
37. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    1. Using a snap ring expander, remove the input gear stopper shaft snap ring.
       Fig 30: Removing Input Gear Stopper Shaft Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
38. REMOVE TRANSFER INPUT GEAR STOPPER 
39. REMOVE TRANSFER INPUT GEAR STOPPER BALL 
40. REMOVE MANUAL TRANSFER PLANETARY CARR WASHER 
    Fig 31: Removing Manual Transfer Planetary Carr Washer

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
41. REMOVE TRANSFER INPUT SHAFT 
42. REMOVE TRANSFER THRUST BEARING RACE NO.1 
43. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    Fig 32: Removing Transfer Low Planetary Gear Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
44. REMOVE TRANSFER INPUT SHAFT SEAL RING NO.1 
    Fig 33: Removing Transfer Input Shaft Seal Ring No.1

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
45. INSPECT TRANSFER INPUT SHAFT 
    1. Using a micrometer, measure the outer diameter of the input shaft journal surface.
       1. Minimum diameter: 47.59 mm (1.8736 in.) 

       If the outer diameter is less than the minimum, replace the input shaft.

       Fig 34: Measuring Outer Diameter Of Input Shaft Journal Surface

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator, measure the inside diameter of the input shaft bushing.
       1. Maximum diameter: 48.14 mm (1.8953 in.) 

    If the inside diameter exceeds the maximum, replace the input shaft.

    Fig 35: Measuring Inside Diameter Of Input Shaft Bushing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
46. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE 
    Fig 36: Measuring Thrust Clearance Of Planetary Pinion Gear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a feeler gauge, measure the thrust clearance of the planetary pinion gear.
       1. Standard clearance: 0.11 - 0.84 mm (0.0043 - 0.0331 in.) 
       2. Maximum clearance: 0.84 mm (0.0331 in.) 

    If the clearance exceeds the maximum, replace the planetary gear assy.

47. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE 
    Fig 37: Measuring Radial Clearance Of Planetary Pinion Gear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a dial indicator, measure the radial clearance of the planetary pinion gear.
       1. Standard clearance: 0.009 - 0.038 mm (0.0004 - 0.0015 in.) 
       2. Maximum clearance: 0.038 mm (0.0015 in.) 

    If the clearance exceeds the maximum, replace the planetary gear assy.

48. REMOVE TRANSFER INPUT SHAFT BEARING 
    1. Using a snap ring expander, remove the snap ring.
    2. Using SST and a press, remove the input shaft bearing.
       1. SST 09554-30011, 09555-55010
    Fig 38: Removing Input Shaft Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
49. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, remove the snap ring.
    2. Remove the low planetary gear spline piece.
       Fig 39: Removing Low Planetary Gear Spline Piece

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
50. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    1. Using SST, remove the low planetary gear bearing.
       1. SST 09612-65014 (09612-01030, 09612-01050)
    NOTE: Hang SST securely to the clearance between the bearing and low planetary gear.
    Fig 40: Removing Low Planetary Gear Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
51. INSPECT DRIVE SPROCKET THRUST CLEARANCE 
    1. Using a feeler gauge, measure the thrust clearance of the drive sprocket.
       1. Standard clearance: 0.15 - 0.24 mm (0.0059 - 0.0094 in.) 
       2. Maximum clearance: 0.24 mm (0.0094 in.) 

    If the clearance exceeds the maximum, replace the drive sprocket.

    Fig 41: Measuring Thrust Clearance Of Drive Sprocket

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
52. INSPECT DRIVE SPROCKET RADIAL CLEARANCE 
    1. Using a dial indicator, measure the radial clearance of the drive sprocket.
       1. Standard clearance: 0.01 - 0.06 mm (0.0004 - 0.0024 in.) 
       2. Maximum clearance: 0.06 mm (0.0024 in.) 

    If the clearance exceeds the maximum, replace the drive sprocket, output shaft rear or needle roller bearing.

    Fig 42: Measuring Radial Clearance Of Drive Sprocket

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
53. REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING 
    1. Using a snap ring expander, remove the snap ring.
54. REMOVE TRANSFER OUTPUT SHAFT SPACER NO.2 
55. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL 
56. REMOVE CENTER DIFFERENTIAL CASE 
    Fig 43: Removing Snap Ring

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
57. REMOVE TRANSFER CLUTCH HUB 
58. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
59. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER 
    Fig 44: Removing Transfer Clutch Hub

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
60. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST and a press, remove the output shaft rear radial ball bearing.
       1. SST 09555-55010
    Fig 45: Removing Output Shaft Rear Radial Ball Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
61. REMOVE TRANSFER OUTPUT SHAFT SPACER NO.1 
62. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSY 
63. REMOVE TRANSFER DRIVE SPROCKET BEARING 
64. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER 
    Fig 46: Removing Transfer Output Shaft Spacer No.1

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
65. INSPECT TRANSFER OUTPUT SHAFT REAR 
    Fig 47: Inspecting Transfer Output Shaft Rear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a micrometer, measure the outer diameter of the output shaft rear journal surface.

       Standard diameter: 

       1. Part A: 27.98 - 27.99 mm (1.1016 - 1.1020 in.) 
       2. Part B: 31.98 - 32.00 mm (1.2591 - 1.2598 in.) 
       3. Part C: 34.98 - 35.00 mm (1.3772 - 1.3780 in.) 
       4. Part D: 36.98 - 37.00 mm (1.4559 - 1.4567 in.) 

       Minimum Diameter: 

       1. Part A: 27.98 mm (1.1016 in.) 
       2. Part B: 31.98 mm (1.2591 in.) 
       3. Part C: 34.98 mm (1.3772 in.) 
       4. Part D: 36.98 mm (1.4559 in.) 

    If the outer diameter is less than the minimum, replace the output shaft rear.

66. INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO.2 CLEARANCE 
    1. Using vernier calipers, measure the thickness of the gear shift fork No.2 claw.
       1. Thickness: 10 mm (0.3937 in.) 
    2. Using vernier calipers, measure the groove of the high and low clutch sleeve.
       1. Distance: 10.5 mm (0.4134 in.) 
    3. Calculate a clearance between the high and low clutch sleeve and gear shift fork No.2 clearance.
       1. Standard clearance: 0.26 - 0.84 mm (0.0102 - 0.0331 in.) 
       2. Maximum clearance: 0.84 mm (0.0331 in.) 

    If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift fork No.2.

    Fig 48: Measuring Groove Of High And Low Clutch Sleeve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
67. INSPECT FRONT DRIVE CLUTCH SLEEVE AND CTR DIFFERENTIAL LOCK FORK SUB-ASSY CLEARANCE 
    1. Using vernier calipers, measure the thickness of the CTR differential lock fork claw.
       1. Thickness: 10 mm (0.397 in.) 
    2. Using vernier calipers, measure the groove of the front drive clutch sleeve.
       1. Distance: 10.5 mm (0.4134 in.) 
    3. Calculate a clearance between the front drive clutch sleeve and CTR differential lock fork.
       1. Standard clearance: 0.26 - 0.84 mm (0.0102 - 0.0331 in.) 
       2. Maximum clearance: 0.84 mm (0.0331 in.) 

    If the clearance exceeds the maximum, replace the front drive clutch sleeve or CTR differential lock fork.

    Fig 49: Measuring Groove Of Front Drive Clutch Sleeve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
68. INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE 
    1. Check that the tip of the spline gear of the high and low clutch sleeve is not worn.
    2. Install the high and low clutch sleeve to the center differential case and check that the high and low clutch sleeve moves smoothly.
    Fig 50: Inspecting Center Differential Case And High And Low Clutch Sleeve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
69. INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE 
    1. Check that the tip of the spline gear of the front drive clutch sleeve is not worn.
    2. Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly.
       Fig 51: Inspecting Center Differential Case And Front Drive Clutch Sleeve

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
70. REMOVE TRANSFER CASE PLUG 
71. REMOVE COMPRESSION SPRING 
72. REMOVE PIN 
    Fig 52: Removing Transfer Case Plug

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
73. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    1. Using a screwdriver, remove the snap ring.
    2. Remove the low planetary ring gear from the front case.
       Fig 53: Removing Low Planetary Ring Gear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
74. INSTALL TRANSFER LOW PLANETARY RING GEAR 
    1. Install the low planetary ring gear to the front case.
       NOTE: Make sure to install the low planetary ring gear in the correct direction.
       Fig 54: Installing Low Planetary Ring Gear To Front Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring.
       Fig 55: Installing Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
75. INSTALL PIN 
76. INSTALL COMPRESSION SPRING 
77. INSTALL TRANSFER CASE PLUG 
    1. Apply sealant to the case plug threads.
       1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    2. Install the case plug.
       1. Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 
    Fig 56: Installing Case Plug

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
78. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER 
79. INSTALL TRANSFER DRIVE SPROCKET BEARING 
80. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSY 
81. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.1 
    Fig 57: Installing Transfer Output Shaft Plate Washer

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
82. INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST and a press, install a new output shaft rear radial ball bearing.
       1. SST 09316-60011 (09316-00011, 09316-00071)
    NOTE: Install the output shaft rear radial ball bearing so that the bearing snap ring groove faces to the rear.
    Fig 58: Installing Output Shaft Rear Radial Ball Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
83. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER 
84. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
85. INSTALL TRANSFER CLUTCH HUB 
    Fig 59: Installing Transfer Output Shaft Plate Washer

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
86. INSTALL CENTER DIFFERENTIAL CASE 
87. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL 
88. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.2 
89. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING 
    1. Using a snap ring expander, install the snap ring.
       Fig 60: Installing Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
90. INSPECT DRIVE SPROCKET RADIAL CLEARANCE 
    1. Using a dial indicator, measure the radial clearance of the drive sprocket.
       1. Standard clearance: 0.01 - 0.06 mm (0.0004 - 0.0024 in.) 
       2. Maximum clearance: 0.06 mm (0.0024 in.) 

    If the clearance exceeds the maximum, replace the drive sprocket, output shaft rear or needle roller bearing.

    Fig 61: Measuring Radial Clearance Of Drive Sprocket

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
91. INSPECT DRIVE SPROCKET THRUST CLEARANCE 
    1. Using a feeler gauge, measure the thrust clearance of the drive sprocket.
       1. Standard clearance: 0.15 - 0.24 mm (0.0059 - 0.0094 in.) 
       2. Maximum clearance: 0.24 mm (0.0094 in.) 

    If the clearance exceeds the maximum, replace the drive sprocket.

    Fig 62: Measuring Thrust Clearance Of Drive Sprocket

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
92. INSTALL TRANSFER INPUT SHAFT BEARING 
    1. Using SST and a press, install a new bearing with the groove facing forward.
       1. SST 09223-15020, 09515-30010, 09950-70010, (09951-07100)
    Fig 63: Installing Bearing With Groove Facing Forward

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
93. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    1. Using SST and a press, drive in a new bearing.
       1. SST 09950-60010 (09951-00570), 09950-70010 (09951-07100)
       1. Bearing press in depth: 7.7 - 8.3 mm (0.303 - 0.327 in.) 
    Fig 64: Installing Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
94. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, install the spline piece with the snap ring.
       Fig 65: Installing Spline Piece With Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
95. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING 
    1. Select a snap ring that allows 0.1 mm (0.0039 in.) or less axial play.
       Fig 66: Snap Ring Specifications Table

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install a new snap ring.
       Fig 67: Selecting Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
96. INSTALL TRANSFER INPUT SHAFT SEAL RING NO.1 

    HINT:

    • Apply gear oil to the 2 oil seal rings.
    • Engage securely to eliminate clearance as shown in the illustration.
    Fig 68: Installing Transfer Input Shaft Seal Ring No.1

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
97. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    NOTE: Make sure to install the transfer low planetary gear bearing in the correct direction.
98. INSTALL TRANSFER THRUST BEARING RACE NO.1 
99. INSTALL TRANSFER INPUT SHAFT 
    Fig 69: Installing Transfer Low Planetary Gear Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
100. INSTALL MANUAL TRANSFER PLANETARY CARR WASHER 
101. INSTALL TRANSFER INPUT GEAR STOPPER BALL 
102. INSTALL TRANSFER INPUT GEAR STOPPER 
     Fig 70: Installing Manual Transfer Planetary Carr Washer

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
103. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
     1. Select a input gear stopper snap ring that allows 0.05 - 0.15 mm (0.0020 - 0.0059 in.) axial play.
        Fig 71: Input Gear Stopper Snap Ring Specifications Table

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     2. Using a snap ring expander, install a new input gear stopper snap ring.
        Fig 72: Selecting Input Gear Stopper Snap Ring

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
104. INSTALL TRANSFER CASE OIL SEAL 
     1. Using SST and a hammer, drive in a new oil seal until its surface is flush with the case upper surface. (No.1)
        1. SST 09316-60011 (09316-00011)
     2. Coat the lip of the oil seal with MP grease.
        Fig 73: Installing Oil Seal

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     3. Using SST and a hammer, drive in a new oil seal until its surface is flush with the case upper surface. (No.2)
        1. SST 09304-12012
        1. Oil seal drive in depth: -0.5 - 0.5 mm (-0.020 - 0.020 in.) 
     4. Coat the lip of the oil seal with MP grease.
        Fig 74: Installing Oil Seal (No.2)

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
105. INSTALL LOW PLANETARY GEAR ASSY W/INPUT SHAFT SUB-ASSY 
     1. Install the low planetary gear assy with input shaft sub-assy.

        HINT:

        If necessary, heat the front case to about 50 - 80°C (122 - 176°F).

        Fig 75: Installing Low Planetary Gear Assy

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     2. Using a snap ring expander, install the snap ring.
        Fig 76: Installing Snap Ring

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
106. INSTALL TRANSFER OIL PUMP GEAR 
     Fig 77: Installing Transfer Oil Pump Gear

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
107. INSTALL TRANSFER OIL PUMP BODY O-RING 
     1. Coat a new O-ring with gear oil and install it to the oil pump body.
        Fig 78: Installing Transfer Oil Pump Body O-Ring

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
108. INSTALL TRANSFER OIL PUMP BODY SUB-ASSY 
     1. Install the oil pump body sub-assy with the 3 bolts.
        1. Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 
     Fig 79: Installing Oil Pump Body Sub-Assy

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
109. INSTALL TRANSFER CASE MAGNET 
110. INSTALL TRANSFER OIL SEPARATOR SUB-ASSY 
     1. Install the oil separator sub-assy with the 3 bolts.
        1. Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 
     Fig 80: Installing Oil Separator Sub-Assy

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
111. INSTALL TRANSFER CASE NO.1 PLUG 
     1. Install the case No.1 plug (filler plug) and a new gasket.
        1. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) 
112. INSTALL TRANSFER CASE NO.1 PLUG 
     1. Install the case No.1 plug (drain plug) and a new gasket.
        1. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) 
113. INSTALL TRANSFER SHIFT ACTUATOR ASSY 
     1. Install the actuator assy with the 3 bolts.
        1. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 
     2. Using a screwdriver and hammer, drive in the 2 snap rings.
     Fig 81: Installing Actuator Assy

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
114. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING 
     1. Using SST and a press, install a new input gear radial ball bearing.
        1. SST 09316-60011 (09316-00031)
     Fig 82: Installing Input Gear Radial Ball Bearing

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
115. INSTALL TRANSFER DRIVEN SPROCKET BEARING 
     1. Using a press, install a new driven sprocket bearing.
        Fig 83: Installing Driven Sprocket Bearing

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
116. INSTALL REAR OUTPUT SHAFT SUB-ASSY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSY 
     1. Install the rear output shaft sub-assy and drive sprocket to the front drive chain.
        Fig 84: Installing Rear Output Shaft Sub-Assy And Drive Sprocket To Front Drive Chain

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     2. Install the rear output shaft sub-assy, front drive chain and driven sprocket sub-assy to the case rear.

        HINT:

        Check that the rear output shaft sub-assy and driven sprocket sub-assy turn lightly.

        If necessary, that the rear case about 50 - 80°C (122 - 176°F).

        Fig 85: Installing Rear Output Shaft Sub-Assy, Front Drive Chain And Driven Sprocket Sub-Assy To Case Rear

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     3. Using a snap ring expander, install the snap ring.
        Fig 86: Installing Snap Ring

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
117. INSTALL CTR DIFFERENTIAL LOCK FORK SUB-ASSY W/FRONT DRIVE CLUTCH SLEEVE 
     1. Install the CTR differential lock fork sub-assy and front drive clutch sleeve.
        Fig 87: Installing CTR Differential Lock Fork Sub-Assy

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     2. Install the bolt.
        1. Torque: 24 N.m (245 kgf.cm, 18 ft.lbf) 
     3. Using a screwdriver and hammer, drive in the snap ring.
     NOTE: Make sure to install the fork and clutch sleeve in the correct direction.
118. INSTALL TRANSFER GEAR SHIFT FORK NO.2 W/TRANSFER HIGH AND LOW CLUTCH SLEEVE 
     1. Install the gear shift fork No.2 and high and low shift fork shaft and high and low clutch sleeve.
        NOTE: Make sure to install the fork in the correct direction.
     2. Apply sealant to the plug No.1 threads.
        1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
     3. Install the spring and ball to the hole.
     4. Install the plug No.1 to the hole.
        1. Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 
     5. Using a pin punch and hammer, Install the slotted pin.
     Fig 88: Installing Slotted Pin

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
119. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
120. INSTALL TRANSFER OUTPUT SHAFT SPACER 
     Fig 89: Installing Transfer Output Shaft Spacer

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
121. INSTALL TRANSFER CASE REAR 
     1. Apply FIPG to the case rear, as shown.
        1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
        Fig 90: Applying FIPG To Case Rear

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     2. Install the 2 clamps and case rear with the 12 bolts.
        1. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 
           Fig 91: Installing Case Rear

           Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
122. INSTALL TRANSFER OUTPUT WASHER 
     1. Install the collar and 2 output washers.
        Fig 92: Installing Collar

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
123. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
     1. Using SST and a hammer, drive in a new oil seal until its surface is flush with the housing upper surface.
        1. SST 09223-46011, 09631-32020
     2. Coat the lip of the oil seal with MP grease.
        Fig 93: Installing Oil Seal

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
124. INSTALL EXTENSION HOUSING ASSY 
     1. Apply FIPG to the extension housing assy rear, as shown.
        1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
     2. Apply sealant to the bolt threads.
        1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
        Fig 94: Applying FIPG To Extension Housing Assy Rear

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     3. Install the extension housing assy with the 5 bolts.
        1. Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 
     Fig 95: Installing Extension Housing Assy

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
125. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
     Fig 96: Installing Transfer Output Shaft Companion Flange Oil Seal

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
     1. Using SST and a hammer, drive in a new oil seal (front).
        1. SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
     2. Coat the lip of the oil seal with MP grease.
126. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
     1. Drive in a new oil seal (rear) in the same way as the oil seal (front).
        1. SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
     2. Coat the lip of the oil seal with MP grease.
127. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSY 
     1. Install the companion flange sub-assy to the drive sprocket sub-assy. (front)
     2. Using SST to hold the companion flange, install a new companion flange lock nut.
        1. SST 09330-00021
        2. Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf) 
     3. Using a chisel and hammer, stake the companion flange lock nut.
128. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSY 
     1. Using SST, install the companion flange sub-assy (rear) in the same way as the companion flange sub-assy. (front).
        1. SST 09330-00021
        2. Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf) 
     Fig 97: Installing Companion Flange Sub-Assy

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
129. INSTALL BREATHER OIL DEFLECTOR 
130. INSTALL TRANSFER CASE COVER SUB-ASSY 
     1. Install the case cover sub-assy with the 4 bolts.
        1. Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 
     Fig 98: Installing Case Cover Sub-Assy

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
131. INSTALL TRANSFER COVER TYPE T OIL SEAL 
     1. Using SST and a hammer, drive in a new oil seal until its surface is flush with the retainer upper surface.
     2. Coat the lip of the oil seal with MP grease.
        1. SST 09950-60010 (09951-00590), 09950-70010 (09951-07100)
        Fig 99: Installing Transfer Cover Type T Oil Seal

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
132. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY 
     1. Apply FIPG to the bearing retainer sub-assy, as shown.
        1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
     2. Apply sealant to the bolt thread.
        Fig 100: Applying FIPG To Bearing Retainer Sub-Assy

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
     3. Install the bearing retainer sub-assy with the 5 bolts.
        1. Torque: 12 N.m (117 kgf.cm, 8 ft.lbf) 
     Fig 101: Installing Bearing Retainer Sub-Assy

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
133. INSTALL TRANSFER GEAR SHIFT HEAD NO.2 
     1. Using a pin punch and hammer, install the slotted pin to the gear shift head No.2.
        Fig 102: Installing Slotted Pin To Gear Shift Head No.2

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
134. INSTALL SWITCH 
     1. Install a new gaskets, the indicator switches and the case No.1 plug.
        1. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) 
     Fig 103: Installing Indicator Switches

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
135. INSTALL HOSES 
     NOTE:

     • Place the hose that passes between the transfer rear case and the actuator motor.
     • Adjust the clamp position to prevent the excessive bent or expansion/contraction of the hose.
     Fig 104: Installing Hoses

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
136. INSTALL TRANSFER ASSY 
     1. Install the transfer to the automatic transmission.
     2. Install the 2 clamps and 8 bolts.
        1. Torque: 24 N.m (245 kgf.cm, 17 ft.lbf) 
137. INSTALL AUTOMATIC TRANSMISSION ASSY 
     1. 2UZ-FE : (See AUTOMATIC TRANSMISSION ASSY (FROM AUGUST, 2003) )
138. INSTALL TRANSFER CASE LOWER PROTECTOR 
     1. Install the 4 bolts with the transfer case lower protector.
        1. Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 
139. ADD TRANSFER OIL (  TRANSFER OIL  )