Transfer Assembly: Disassembly

REMOVE BREATHER HOSE
REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR
Remove the bolt and driven gear.
REMOVE MOTOR ACTUATOR
Remove the 4 bolts and motor actuator.

Fig 1: Locating Bolts Motor Actuator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT GEAR FROM FRONT CASE

Fig 2: Removing Output Gear From Front
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SCREW PLUG, SPRING AND BALL
1. Using a torx socket wrench (T40), remove the screw plug.
2. Using a magnetic finger, remove the spring and ball.
Fig 3: Removing Screw Plug, Spring And Ball
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INDICATOR SWITCH
Remove the 3 transfer indicator switches and 3 gaskets.
REMOVE FRONT EXTENSION HOUSING
Remove the 6 bolts and front extension housing.

HINT:

If necessary, tap the front extension housing lightly with a plastic hammer.

Fig 4: Identifying Front Extension Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH SLEEVE WITH SHIFT FORK NO. 2 SHAFT AND SHIFT FORK NO. 2

Fig 5: Removing Clutch Sleeve With Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE SHIFT FORK NO. 2 SHAFT AND SHIFT FORK NO. 2
1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the shift fork No. 2 shaft.
2. Separate the shift fork No. 2 shaft and shift fork No. 2.
Fig 6: Taping Out Snap Rings From Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR EXTENSION HOUSING
Remove the 9 bolts and rear extension housing.

HINT:

If necessary, tap the rear extension housing lightly with a plastic hammer.

Fig 7: Locating Rear Extension Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ADJUSTING SHIMS
REMOVE OIL STRAINER FROM REAR CASE
Remove the 2 bolts and oil strainer.

Fig 8: Locating Oil Strainer Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CASE COVER
1. Remove the 5 bolts.
  
  Fig 9: Identifying Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap the case cover and remove it.
Fig 10: Taping Case Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE FRONT CASE AND REAR CASE
1. Using a snap ring expander, remove the snap ring from the rear case.
  
  Fig 11: Removing Snap Ring From Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 8 bolts.
3. Using a brass bar and hammer, tap the rear case and separate it.
Fig 12: Locating Rear Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2 BEARING RACES FROM REAR CASE

Fig 13: Removing Bearing Races From Rear Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT ASSEMBLY
Using a plastic hammer, remove the input shaft assembly from the front case.

Fig 14: Removing Input Shaft Assembly From Front Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND SHIFT FORK NO. 1 SHAFT FROM FRONT CASE

Fig 15: Removing Idler Gear Assembly With Center Differential Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE SHIFT FORK NO. 1 AND SHIFT FORK NO. 1 SHAFT
1. Using a pin punch and hammer, drive out the slotted spring pin.
2. Separate the shift fork No. 1 and shift fork No. 1 shaft.
Fig 16: Driving Out Slotted Spring Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT OUTER LEVER AND INNER LEVER
1. Remove the nut and washer from the shift outer lever.
2. Using a brass bar, hammer and socket wrench, tap out the lever lock pin.
3. Remove the shift outer lever, washer and inner lever from the front case.
Fig 17: Taping Out Lever Lock Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
IF NECESSARY, REPLACE INNER SHIFT LEVER OIL SEAL
1. Using a screwdriver, pry out the oil seal from the front case.
  
  Fig 18: Prying Out Oil Seal From Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply MP grease to the lip of a new oil seal.
3. Using SST and a hammer, drive in a new oil seal.
  SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)
  
  Fig 19: Driving In New Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL
1. Using SST and a hammer, drive out the oil seal.
  SST 09316-6001 1 (09316-00011)
2. Apply MP grease to the lip of a new oil seal.
3. Using SST and a hammer, drive in a new oil seal.
  SST 09316-6001 1 (09316-00011, 09316-00031)
Fig 20: Driving Out Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL RECEIVER FROM FRONT CASE
Remove the bolt and oil receiver.

Fig 21: Removing Oil Receiver From Front Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2 BEARING RACES FROM FRONT CASE
1. Using SST, remove the bearing race (for the idler gear).
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010), 09950-60010 (09951-00320)
  
  Fig 22: Removing Bearing Race (For Idler Gear)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, remove the bearing race (for the output shaft).
Fig 23: Removing Bearing Race (For Output Shaft)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002