Transfer ASSY: Overhaul

HINT:

DRAIN TRANSFER OIL
REMOVE TRANSFER CASE LOWER PROTECTOR
1. Remove the 4 bolts and transfer case lower protector.
  
  Fig 1: Removing Bolts & Transfer Case Lower Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AUTOMATIC TRANSMISSION ASSY
1. 2UZ-FE: See REPLACEMENT
REMOVE TRANSFER ASSY
1. Remove the 8 bolts and 2 clamps from the transmission.
  
  Fig 2: Removing Bolts & Clamps From Transmission
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HOSES
1. Remove an actuator motor breather hose.
  
  Fig 3: Removing Actuator Motor Breather Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SWITCH
1. Remove the indicator No. 1 and No. 2 switches, case No. 1 plug and gaskets.
  
  Fig 4: Removing Indicator No. 1 & No. 2 Switches, Case No. 1 Plug & Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 From Gear Shift Head No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Bolts & Bearing Retainer Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER COVER TYPE T OIL SEAL
1. Using a screwdriver and hammer, remove the oil seal from the bearing retainer sub-assy.
REMOVE TRANSFER CASE COVER SUB-ASSY
1. Remove the 4 bolts and case cover sub-assy.
REMOVE BREATHER OIL DEFLECTOR

Fig 7: Removing Bolts & Case Cover Sub-Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  SST 09330-00021
  
  Fig 8: Removing Output Shaft Companion Flange Lock Nut Using SST To Hold Output Shaft Companion Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, remove the output shaft companion flange sub-assy (front).
  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 (Front) Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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).
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).
  SST 09330-00021, 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
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).
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.
  
  Fig 10: Removing Bolts & Extension Housing Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
1. Using a screwdriver and hammer, remove the oil seal.
REMOVE TRANSFER OUTPUT WASHER
1. Remove the 2 output washers and collar.
  
  Fig 11: Removing Output Washers & Collar
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Bolts & Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
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.
  
  Fig 13: Removing Plug No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Tapping Out Snap Ring Using Screwdrivers & Hammer
  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, CTR Differential Lock Fork Sub-Assy & Front Drive Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Using Snap Ring Expander
  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 Together With Front Drive Chain & Driven Sprocket 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: Identifying Rear Output Shaft Sub-Assy, Front Drive Chain & Driven Sprocket Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVEN SPROCKET BEARING
1. Using a press, remove the driven sprocket bearing.
  
  Fig 19: Removing Driven Sprocket Bearing Using Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING
1. Using SST, a press and steel bar, remove the transfer input gear radial ball bearing.
  SST 09555-55010
  
  Fig 20: Removing Transfer Input Gear Radial Ball Bearing Using SST, Press & Steel Bar
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER SHIFT ACTUATOR ASSY
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  
  Fig 21: Tapping Out Snap Ring Using Screwdrivers & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 bolts and transfer shift actuator assy.
  
  Fig 22: Removing Bolts & Transfer Shift Actuator Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE NO. 1 PLUG
1. Remove the transfer case plug No. 1 (filler plug) and gasket.
REMOVE TRANSFER CASE NO. 1 PLUG
1. Remove the transfer case plug No. 1 (drain plug) and gasket.
REMOVE TRANSFER OIL SEPARATOR SUB-ASSY
1. Remove the 3 bolts and oil separator sub-assy.
  
  Fig 23: Removing Bolts & Oil Separator Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE MAGNET
REMOVE TRANSFER OIL PUMP BODY SUB-ASSY
1. Remove the 3 bolts and oil pump body sub-assy.
  
  Fig 24: Removing Bolts & Oil Pump Body Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OIL PUMP GEAR

Fig 26: Removing Transfer Oil Pump Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Using Snap Ring Expander
  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 & Input Shaft Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT SHAFT SPACER
REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING

Fig 29: Removing Transfer Output Shaft Front Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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).
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 Using Snap Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT GEAR STOPPER
REMOVE TRANSFER INPUT GEAR STOPPER BALL
REMOVE MANUAL TRANSFER PLANETARY CARR WASHER

Fig 31: Removing Transfer Input Gear Stopper Ball
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT SHAFT
REMOVE TRANSFER THRUST BEARING RACE NO. 1
REMOVE TRANSFER LOW PLANETARY GEAR BEARING

Fig 32: Removing Transfer Low Planetary Gear Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT SHAFT SEAL RING NO. 1

Fig 33: Removing Transfer Input Shaft Seal Ring No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER INPUT SHAFT
1. Using a micrometer, measure the outer diameter of the input shaft journal surface.
  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 Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the inside diameter of the input shaft bushing.
  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 Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PLANETARY PINION GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the thrust clearance of the planetary pinion gear.
  Standard clearance:
  
  0.11 - 0.84 mm (0.0043 - 0.0331 in.)
  
  Maximum clearance:
  
  0.84 mm (0.0331 in.)
  
  If the clearance exceeds the maximum, replace the planetary gear assy.
  
  Fig 36: Measuring Thrust Clearance Of Planetary Pinion Gear Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the radial clearance of the planetary pinion gear.
  Standard clearance:
  
  0.009 - 0.038 mm (0.0004 - 0.0015 in.)
  
  Maximum clearance:
  
  0.038 mm (0.0015 in.)
  
  If the clearance exceeds the maximum, replace the planetary gear assy.
  
  Fig 37: Measuring Radial Clearance Of Planetary Pinion Gear Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  SST 09554-3001 1, 09555-55010
  
  Fig 38: Removing Input Shaft Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Snap Ring Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER LOW PLANETARY GEAR BEARING
1. Using SST, remove the low planetary gear bearing.
  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 Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DRIVE SPROCKET THRUST CLEARANCE
1. Using a feeler gauge, measure the thrust clearance of the drive sprocket.
  Standard clearance:
  
  0.15 - 0.24 mm (0.0059 - 0.0094 in.)
  
  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 Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DRIVE SPROCKET RADIAL CLEARANCE
1. Using a dial indicator, measure the radial clearance of the drive sprocket.
  Standard clearance:
  
  0.01 - 0.06 mm (0.0004 - 0.0024 in.)
  
  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 Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING
1. Using a snap ring expander, remove the snap ring.
REMOVE TRANSFER OUTPUT SHAFT SPACER NO. 2
REMOVE TRANSFER OUTPUT SHAFT SPACER BALL
REMOVE CENTER DIFFERENTIAL CASE

Fig 43: Removing Snap Ring Using Snap Ring Expander
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CLUTCH HUB
REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER

Fig 44: Removing Transfer Output Shaft Plate Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING
1. Using SST and a press, remove the output shaft rear radial ball bearing.
  SST 09555-55010
  
  Fig 45: Removing Output Shaft Rear Radial Ball Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT SHAFT SPACER NO. 1
REMOVE TRANSFER DRIVE SPROCKET SUB-ASSY
REMOVE TRANSFER DRIVE SPROCKET BEARING
REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER

Fig 46: Removing Transfer Drive Sprocket Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER OUTPUT SHAFT REAR
1. Using a micrometer, measure the outer diameter of the output shaft rear journal surface.
  Standard diameter:
  
  Part A: 27.98 - 27.99 mm (1.1016 - 1.1020 in.)
  
  Part B: 31.98 - 32.00 mm (1.2591 - 1.2598 in.)
  
  Part C: 34.98 - 35.00 mm (1.3772 - 1.3780 in.)
  
  Part D: 36.98 - 37.00 mm (1.4559 - 1.4567 in.)
  
  Minimum Diameter:
  
  Part A: 27.98 mm (1.1016 in.)
  
  Part B: 31.98 mm (1.2591 in.)
  
  Part C: 34.98 mm (1.3772 in.)
  
  Part D: 36.98 mm (1.4559 in.)
  
  If the outer diameter is less than the minimum, replace the output shaft rear.
  
  Fig 47: Measuring Outer Diameter Of Output Shaft Rear Journal Surface Using Micrometer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  Thickness: 10 mm (0.3937 in.)
2. Using vernier calipers, measure the groove of the high and low clutch sleeve.
  Distance: 10.5 mm (0.4134 in.)
  
  Fig 48: Measuring Thickness Of Gear Shift Fork No. 2 Claw Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Calculate a clearance between the high and low clutch sleeve and gear shift fork No. 2 clearance.
  Standard clearance:
  
  0.26 - 0.84 mm (0.0102 - 0.0331 in.)
  
  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.
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.
  Thickness: 10 mm (0.397 in.)
2. Using vernier calipers, measure the groove of the front drive clutch sleeve.
  Distance: 10.5 mm (0.4134 in.)
3. Calculate a clearance between the front drive clutch sleeve and CTR differential lock fork.
  Standard clearance:
  
  0.26 - 0.84 mm (0.0102 - 0.0331 in.)
  
  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 Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Checking Tip Of Spline Gear Of High & Low Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Checking Tip Of Spline Gear Of Front Drive Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE PLUG
REMOVE COMPRESSION SPRING
REMOVE PIN

Fig 52: Removing Transfer Case Plug, Compression Spring & Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Snap Ring Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PIN
INSTALL COMPRESSION SPRING
INSTALL TRANSFER CASE PLUG
1. Apply sealant to the case plug threads.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
2. Install the case plug.
  Torque: 19 N.m (190 kgf.cm, 14 ft.lbf)
  
  Fig 56: Installing Pin, Compression Spring & Transfer Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER
INSTALL TRANSFER DRIVE SPROCKET BEARING
INSTALL TRANSFER DRIVE SPROCKET SUB-ASSY
INSTALL TRANSFER OUTPUT SHAFT SPACER NO. 1

Fig 57: Installing Transfer Drive Sprocket Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING
1. Using SST and a press, install a new output shaft rear radial ball bearing.
  SST 09316-6001 1 (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 New Output Shaft Rear Radial Ball Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER
INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
INSTALL TRANSFER CLUTCH HUB

Fig 59: Installing Transfer Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER DIFFERENTIAL CASE
INSTALL TRANSFER OUTPUT SHAFT SPACER BALL
INSTALL TRANSFER OUTPUT SHAFT SPACER NO. 2
INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING
1. Using a snap ring expander, install the snap ring.
  
  Fig 60: Installing Transfer Low Planetary Ring Gear Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DRIVE SPROCKET RADIAL CLEARANCE
1. Using a dial indicator, measure the radial clearance of the drive sprocket.
  Standard clearance:
  
  0.01 - 0.06 mm (0.0004 - 0.0024 in.)
  
  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 Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DRIVE SPROCKET THRUST CLEARANCE
1. Using a feeler gauge, measure the thrust clearance of the drive sprocket.
  Standard clearance:
  
  0.15 - 0.24 mm (0.0059 - 0.0094 in.)
  
  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 Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER INPUT SHAFT BEARING
1. Using SST and a press, install a new bearing with the groove facing forward.
  SST 09223-15020, 09515-30010, 09950-70010 (09951-07100)
  
  Fig 63: Installing New Bearing With Groove Facing Forward Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER LOW PLANETARY GEAR BEARING
1. Using SST and a press, drive in a new bearing.
  SST 09950-60010 (09951-00570), 09950-70010 (09951-07100)
  
  Bearing press in depth:
  
  7.7 - 8.3 mm (0.303 - 0.327 in.)
  
  Fig 64: Installing New Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING

Select a snap ring that allows 0.1 mm (0.0039 in.) or less axial play.

SNAP RING THICKNESS SPECIFICATION

Mark	Thickness mm (in.)
1	1.45 - 1.50 (0.0571 - 0.0591)
2	1.50 - 1.55 (0.0591 - 0.0610)
3	1.55 - 1.60 (0.0610 - 0.0630)
4	1.60 - 1.65 (0.0630 - 0.0650)
5	1.65 - 1.70 (0.0650 - 0.0669)

Fig 66: Installing Transfer Input Bearing Shaft Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a snap ring expander, install a new snap ring.

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 Fig 67.
  
  Fig 67: Checking Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER LOW PLANETARY GEAR BEARING
NOTE: Make sure to install the transfer low planetary gear bearing in the correct direction.
INSTALL TRANSFER THRUST BEARING RACE NO. 1
INSTALL TRANSFER INPUT SHAFT

Fig 68: Installing Transfer Low Planetary Gear Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSFER PLANETARY CARR WASHER
INSTALL TRANSFER INPUT GEAR STOPPER BALL
INSTALL TRANSFER INPUT GEAR STOPPER

Fig 69: Installing Transfer Input Gear Stopper Ball
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING

Select a input gear stopper snap ring that allows 0.05 - 0.15 mm (0.0020 - 0.0059 in.) axial play.

SNAP RING THICKNESS SPECIFICATION

Mark	Thickness mm (in.)
A	2.10 - 2.15 (0.0827 - 0.0846)
B	2.15 - 2.20 (0.0846 - 0.0866)
C	2.20 - 2.25 (0.0866 - 0.0886)
D	2.25 - 2.30 (0.0886 - 0.0906)
LJJ	2.30 - 2.35 (0.0906 - 0.0925)
F	2.35 - 2.40 (0.0925 - 0.0945)
G	2.40 - 2.45 (0.0945 - 0.0965)
H	2.45 - 2.50 (0.0965 - 0.0984)
J	2.50 - 2.55 (0.0984 - 0.1004)
K	2.55 - 2.60 (0.1004 - 0.1204)
L	2.60 -2.65 (0.1024 - 0.1043)
M	2.65 - 2.70 (0.1043 - 0.1063)
N	2.70 - 2.75 (0.1063 - 0.1083)
P	2.75 - 2.80 (0.1083 - 0.1102)
Q	2.80 - 2.85 (0.1102 - 0.1122)
R	2.85 - 2.90 (0.1122 - 0.1142)
S	2.90 - 2.95 (0.1142 - 0.1161)
T	2.95 - 3.00 (0.1161 -0.1181)
U	3.00 - 3.05 (0.1181 - 0.1201)

Fig 70: Installing Transfer Input Gear Stopper Shaft Snap Ring

Using a snap ring expander, install a new input gear stopper snap ring.

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)
  SST 09316-6001 1 (09316-00011)
2. Coat the lip of the oil seal with MP grease.
  
  Fig 71: Installing New Oil Seal Using SST & Hammer (No. 1)
  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)
  SST 09304-12012
  
  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 72: Installing New Oil Seal Using SST & Hammer (No. 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 73: Installing Low Planetary Gear Assy With Input Shaft Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, install the snap ring.
  
  Fig 74: Installing Snap Ring Using Snap Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OIL PUMP GEAR

Fig 75: Installing Transfer Oil Pump Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 76: Installing New Transfer Oil Pump Body O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OIL PUMP BODY SUB-ASSY
1. Install the oil pump body sub-assy with the 3 bolts.
  Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
  
  Fig 77: Installing Oil Pump Body Sub-Assy With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE MAGNET
INSTALL TRANSFER OIL SEPARATOR SUB-ASSY
1. Install the oil separator sub-assy with the 3 bolts.
  Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
  
  Fig 78: Installing Oil Separator Sub-Assy With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE NO. 1 PLUG
1. Install the case No. 1 plug (filler plug) and a new gasket.
  Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
INSTALL TRANSFER CASE NO. 1 PLUG
1. Install the case No. 1 plug (drain plug) and a new gasket.
  Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
INSTALL TRANSFER SHIFT ACTUATOR ASSY
1. Install the actuator assy with the 3 bolts.
  Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
2. Using a screwdriver and hammer, drive in the 2 snap rings.
  
  Fig 79: Installing Actuator Assy With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING
1. Using SST and a press, install a new input gear radial ball bearing.
  SST 09316-6001 1 (09316-00031)
  
  Fig 80: Installing New Input Gear Radial Ball Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DRIVEN SPROCKET BEARING
1. Using a press, install a new driven sprocket bearing.
  
  Fig 81: Installing New Driven Sprocket Bearing Using Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 82: Identifying Rear Output Shaft Sub-Assy & 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, heat the rear case to about 50 - 80°C (122 - 176°F).
  
  Fig 83: Installing Rear Output Shaft Sub-Assy, Front Drive Chain & Driven Sprocket Sub-Assy To Case Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a snap ring expander, install the snap ring.
  
  Fig 84: Installing Snap Ring Using Snap Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
2. Install the bolt.
  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.
  
  Fig 85: Installing Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 86: Installing Gear Shift Fork No. 2, High & Low Shift Fork Shaft & High & Low Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply sealant to the plug No. 1 threads.
  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.
  Torque: 19 N.m (190 kgf.cm, 14 ft.lbf)
5. Using a pin punch and hammer, Install the slotted pin.
INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
INSTALL TRANSFER OUTPUT SHAFT SPACER

Fig 87: Installing Plug No. 1 To Hole
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE REAR
1. Apply FIPG to the case rear, as shown in Fig 88.
  FIPG:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
  
  Fig 88: Applying FIPG To Case Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 clamps and case rear with the 12 bolts.
  Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)
  
  Fig 89: Installing Clamps & Case Rear With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OUTPUT WASHER
1. Install the collar and 2 output washers.
  
  Fig 90: Installing Collar & Output Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  SST 09223-4601 1, 09631-32020
2. Coat the lip of the oil seal with MP grease.
  
  Fig 91: Installing New Transfer Extension Housing Type T Oil Seal Using SST & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXTENSION HOUSING ASSY
1. Apply FIPG to the extension housing assy rear, as shown in Fig 92.
  FIPG:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
2. Apply sealant to the bolt threads.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Fig 92: Applying FIPG To Extension Housing Assy Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the extension housing assy with the 5 bolts.
  Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)
  
  Fig 93: Installing Extension Housing Assy With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
1. Using SST and a hammer, drive in a new oil seal (front).
  SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
2. Coat the lip of the oil seal with MP grease.
  
  Fig 94: Installing New Transfer Output Shaft Companion Flange Oil Seal Using SST & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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).
  SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
2. Coat the lip of the oil seal with MP grease.
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.
  SST 09330-00021
  
  Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf)
3. Using a chisel and hammer, stake the companion flange lock nut.
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).
  SST 09330-00021
  
  Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf)
  
  Fig 95: Installing Companion Flange Lock Sub-Assy Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BREATHER OIL DEFLECTOR
INSTALL TRANSFER CASE COVER SUB-ASSY
1. Install the case cover sub-assy with the 4 bolts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
  
  Fig 96: Installing Case Cover Sub-Assy With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  SST 09950-60010 (09951-00590), 09950-70010 (09951-07100)
  
  Fig 97: Installing New Transfer Cover Type T Oil Seal Using SST & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY
1. Apply FIPG to the bearing retainer sub-assy, as shown in Fig 98.
  FIPG:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
2. Apply sealant to the bolt thread.
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Fig 98: Applying FIPG To Bearing Retainer Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the bearing retainer sub-assy with the 5 bolts.
  Torque: 12 N.m (117 kgf.cm, 8 ft.lbf)
  
  Fig 99: Installing Bearing Retainer Sub-Assy With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 100: Installing Slotted Pin To Gear Shift Head No. 2 Using Pin Punch & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SWITCH
1. Install a new gasket, the indicator switches and the case No. 1 plug.
  Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
  
  Fig 101: Installing New Gasket, Indicator Switches & Case No. 1 Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 102: Installing Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER ASSY
1. Install the transfer to the automatic transmission.
2. Install the 2 clamps and 8 bolts.
  Torque: 24 N.m (245 kgf.cm, 18 ft.lbf)
INSTALL AUTOMATIC TRANSMISSION ASSY
1. 2UZ-FE: See REPLACEMENT
INSTALL TRANSFER CASE LOWER PROTECTOR
1. Install the 4 bolts with the transfer case lower protector.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
ADD TRANSFER OIL (See ADJUSTMENT )