Transfer Assembly: Reassembly

WARNING: This page is about a different car, the 2006 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL CENTER DIFFERENTIAL CLUTCH CONTROL VALVE
1. Install the center differential clutch control valve sleeve, transfer direct clutch modulator valve spring, center differential clutch control valve and center differential clutch control valve plug to the transfer upper valve body.
  
  Fig 1: Installing Center Differential Clutch Control Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. While pushing on the center differential control valve plug, install the center differential clutch control valve seat on the transfer upper valve body.
  
  Fig 2: Installing Center Differential Clutch Control Valve Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER SOLENOID MODULATOR VALVE
1. Install the low-high shift valve compression spring, transfer solenoid modulator valve and transfer solenoid modulator valve plug to the transfer upper valve body.
  
  Fig 3: Installing Transfer Solenoid Modulator Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. While pushing on the transfer solenoid modulator valve plug, install the transfer solenoid modulator valve plug seat on the transfer upper valve body.
Fig 4: Installing Transfer Solenoid Modulator Valve Plug Seat
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER VALVE BODY COVER
1. Install the solenoid oil strainer to the transfer valve body cover.
2. Install the transfer valve body cover and upper transfer valve body plate to the transfer upper valve body.
  
  Fig 5: Installing Transfer Valve Body Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 6 bolts.
Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)

HINT:

Bolt length:
- Bolt A: 35 mm (1.38 in.)
- Bolt B: 20 mm (0.79 in.)
Fig 6: Installing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CONTROL SOLENOID
1. Install the transfer control solenoid and solenoid lock plate to the transfer upper valve body with the bolt.
Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)

HINT:

Install the solenoid lock plate into the cutout on the transfer control solenoid.

Fig 7: Installing Transfer Control Solenoid
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DRIVE SPROCKET BEARING
1. Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket.
  SST 09950-70010 (09951-07100), 09950-60010 (09951-00640), 09316-20011
  
  Fig 8: Installing Transfer Drive Sprocket Bearing Using SST (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket.
SST 09316-60011 (09316-00011)

NOTE: Install the transfer drive sprocket bearing with the shield facing upward.

Fig 9: Installing Transfer Drive Sprocket Bearing Using SST (2 Of 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DRIVEN SPROCKET BEARING
1. Using SST and a press, install a new transfer driven sprocket bearing to the transfer front driven clutch sleeve.
  SST 09950-70010 (09951-07100), 09950-60010 (09951-00640), 09316-20011
  
  Fig 10: Installing Transfer Driven Sprocket Bearing Using SST (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new transfer driven sprocket bearing to the transfer front driven clutch sleeve.
SST 09316-60011 (09316-00011, 09316-00041)

Fig 11: Installing Transfer Driven Sprocket Bearing Using SST (2 Of 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CENTER SUPPORT SEAL RING
1. Coat the 2 seal rings with ATF.
2. Compress the 2 transfer center support seal rings as shown in Fig 12 and install them into the grooves on the transfer center support.
Fig 12: Compressing Transfer Center Support Seal Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- Do not expand the ring ends excessively.
- If any ring is damaged or deformed, replace it with a new one.
INSTALL TRANSFER CENTER SUPPORT
1. Install the transfer center support to the rear transfer chain case with the 5 bolts.
  Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
2. Coat 2 new O-rings with ATF.
3. Install the 2 O-rings to the screws.
4. Install the 2 gaskets and 2 screws to the rear transfer chain case.
Fig 13: Installing Transfer Center Support
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)

INSTALL TRANSFER DIRECT CLUTCH PISTON O-RING

Coat 2 new O-rings with ATF.
Install the 2 O-rings to the transfer direct clutch piston.

Fig 14: Installing O-Rings To Transfer Direct Clutch Piston

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

O-ring size:

O-RING SPECIFICATIONS

Installation position	Inner diameter mm (in.)	Thickness mm (in.)
Inner	56.45 to 57.45 (2.222 to 2.262)	2.54 to 2.70 (0.100 to 0.106)
Outer	116.20 to 117.80 (4.575 to 4.638)	3.0 to 3.2 (0.118 to 0.126)

INSTALL CENTER DIFFERENTIAL CLUTCH PISTON
1. Install the transfer differential clutch piston to the transfer direct clutch drum.
NOTE: Do not damage the O-rings.

Fig 15: Installing Center Differential Clutch Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DIRECT CLUTCH RETURN SPRING
1. Install the transfer direct clutch return spring to the transfer direct clutch drum.
Fig 16: Installing Transfer Direct Clutch Return Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER
1. Coat the rubber on the center differential clutch pressure balancer with ATF.
2. Install the center differential clutch pressure balancer to the transfer direct clutch drum.
  
  Fig 17: Identifying Rubber
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place SST on the center differential clutch pressure balancer, and compress the return spring with a press.
  SST 09350-30020 (09350-07040)
4. Using SST, install the snap ring.
SST 09350-30020 (09350-07040, 09350-07070)

Fig 18: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CENTER DIFFERENTIAL CLUTCH DISC SET

Install the 2 center differential clutch disc flanges and center differential clutch disc set to the transfer direct clutch drum.
HINT:
- A: Center differential clutch disc flange (No. 1)
- B: Center differential clutch disc set (Discs)
  
  Fig 19: Installing Center Differential Clutch Disc Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- C: Center differential clutch disc set (Plates)
- D: Center differential clutch disc flange (No. 2)
Install in the following order:

A - B - C - B - C - B - C - B - C - B - D

HINT:
- A: thickness 2.95 to 3.45 mm (0.116 to 0.136 in.)
- B: thickness 1.99 to 2.09 mm (0.078 to 0.082 in.)
- C: thickness 1.95 to 2.05 mm (0.077 to 0.081 in.)
- D: thickness 2.95 to 3.05 mm (0.116 to 0.120 in.)
NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
Using a screwdriver with its tip taped, install the snap ring to the transfer direct clutch drum.

Fig 20: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the transfer direct clutch drum to the transfer center support.

Fig 21: Installing Transfer Direct Clutch Drum To Transfer Center Support
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Set the dial indicator perpendicular to the flange.
Apply air (200 kpa, 2.0 kgf*cm² , 19 psi) into the oil hole as shown in Fig 22. Measure the pack clearance.
Standard:

0.40 to 0.80 mm (0.016 to 0.031 in.)

Fig 22: Measuring Pack Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:
- Check that the piston moves smoothly.
- Perform the measurement at 2 or 3 points and take the average.

If the clearance is not within the specified range, select another center differential clutch disc flange (No. 1).

Flange thickness:

FLANGE THICKNESS REFERENCE

Thickness mm (in.)	Mark
2.95 to 3.05 (0.116 to 0.120)	90
3.15 to 3.25 (0.124 to 0.128)	91
3.35 to 3.45 (0.132 to 0.136)	92

Fig 23: Identifying Clutch Flange Thickness

Remove the transfer direct clutch drum from the transfer center support.

Fig 24: Removing Transfer Direct Clutch Drum From Transfer Center Support

INSTALL TRANSFER REAR OUTPUT SHAFT BEARING
1. Install the transfer rear output shaft bearing to the transfer direct clutch drum.
Fig 25: Installing Transfer Rear Output Shaft Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER DIFFERENTIAL CARRIER
1. Install the center differential carrier to the transfer rear output shaft and transfer direct clutch drum.
Fig 26: Installing Center Differential Carrier
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE FRONT OIL SEAL
1. Using SST and a hammer, install a new oil seal.
  SST 09316-60011 (09316-00011, 09316-00071)
  
  Oil seal installation depth:
  
  5.6 to 6.2 mm (0.220 to 0.244 in.)
2. Apply MP grease to the oil seal lip.
Fig 27: Installing Transfer Case Front Oil Seal Using SST & Hammer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CHAIN CASE GOVERNOR APPLY GASKET
1. Coat 2 new gaskets with ATF.
2. Install the 2 gaskets to the rear transfer chain case.
  
  Fig 28: Installing Transfer Chain Case Governor Apply Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat a new O-ring and 2 new gaskets with ATF.
4. Install the O-ring to the screw and install it.
5. Install the 2 gaskets and screw to the front transfer chain case.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)

Fig 29: Installing Gaskets & Screw To Transfer Chain Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER BAFFLE VALVE SUB-ASSEMBLY
1. Install the transfer baffle valve to the rear transfer chain case with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

Fig 30: Installing Transfer Baffle Valve Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE BEARING
1. Using SST and a press, install the transfer case bearing to the transfer case.
SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)

Bearing installation depth:

94.6 to 94.9 mm (3.724 to 3.736 in.)

Fig 31: Installing Transfer Case Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE REAR OIL SEAL
1. Using SST and a hammer, install a new oil seal.
  SST 09325-40010
  
  Oil seal installation depth:
  
  2.3 to 2.7 mm (0.091 to 0.106 in.)
  
  Fig 32: Installing New Oil Seal Using SST & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply MP grease to the oil seal lip.
3. Install the clamp to the transfer case with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

Fig 33: Installing Clamp To Transfer Case With Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR
1. Using SST and a press, install a new transfer extension housing dust deflector to the transfer case.
SST 09950-70010 (09951-07150), 09950-60020 (09951-00910)

Fig 34: Installing Transfer Extension Housing Dust Deflector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT TRANSFER CHAIN CASE
1. Remove all residual FIPG material from the contact surfaces using gasoline or alcohol.
2. Apply seal packing to the front transfer chain case as shown in Fig 35 .
  
  Fig 35: Applying Seal Packing To Front Transfer Chain Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
3. Temporarily tighten the 6 bolts in several steps, and then tighten them to the specified torque.
Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf)

HINT:

Bolt length:

Fig 36: Tightening 6 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Bolt A: 57 mm (2.24 in.)
- Bolt B: 74 mm (2.91 in.)
- Other bolts: 45 mm (1.77 in.)
INSTALL TRANSFER FRONT DRIVE CHAIN
1. Install the transfer front drive chain to the transfer drive sprocket and transfer front driven clutch sleeve.
2. Install the transfer front drive chain, transfer drive sprocket and transfer front drive clutch sleeve.
Fig 37: Installing Transfer Front Drive Chain
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR TRANSFER CHAIN CASE
1. Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol.
2. Apply seal packing to the transfer chain case front as shown in Fig 38 .
  
  Fig 38: Applying Seal Packing To Transfer Chain Case Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
3. Temporarily tighten the 10 bolts in several steps, and then tighten to the specified torque.
Torque: Bolt (A)

57 N*m (580 kgf*cm, 42 ft.*lbf)

Except bolt (A)

34 N*m (345 kgf*cm, 25 ft.*lbf)

HINT:

Fig 39: Tightening 10 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt length:
- Bolt A: 60 mm (2.36 in.)
- Bolt B: 50 mm (1.97 in.)
- Bolt C: 109 mm (4.29 in.)
- Other bolts: 40 mm (1.57 in.)
INSTALL FLANGE YOKE
1. Install the flange yoke.
2. Using SST, hold the yoke.
  SST 09213-54015, 09330-00021
3. Using a deep socket wrench (30 mm), torque a new nut.
  Torque: 123 N*m (1,250 kgf*cm, 91 ft.*lbf)
4. Using a chisel and hammer, stake the nut.
Fig 40: Installing Flange Yoke
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER REAR OUTPUT SHAFT ASSEMBLY
1. Install the transfer rear output shaft.
Fig 41: Installing Transfer Rear Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE
1. Remove all residual FIPG material from the contact surfaces using gasoline or alcohol.
2. Apply seal packing to the transfer chain case front as shown in Fig 42 .
  
  Fig 42: Applying Seal Packing To Transfer Chain Case Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
3. Temporarily tighten the 8 bolts and clamp in several steps, and then tighten them to the specified torque.
  Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf)
  
  HINT:
  
  Bolt length:
  - Bolt A: 88 mm (3.46 in.)
  - Bolt B: 40 mm (1.57 in.)
  Fig 43: Tightening 8 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER VALVE BODY ASSEMBLY
1. Coat the transfer wire O-ring with ATF.
  
  Fig 44: Locating Transfer Wire O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transfer wire with the bolt.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 45: Installing Transfer Wire With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the transfer wire connector to the transfer control solenoid.
4. Install the transfer valve body assembly with the 4 bolts.
Fig 46: Installing Transfer Valve Body Assembly With 4 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
INSTALL TRANSFER OIL PAN
1. Install the transfer oil cleaner magnet to the transfer oil pan.
  
  Fig 47: Identifying Transfer Oil Cleaner Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove all residual FIPG material from the contact surfaces using gasoline or alcohol.
3. Apply seal packing to the transfer chain case front as shown in Fig 48 .
  
  Fig 48: Applying Seal Packing To Transfer Chain Case Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
4. Temporarily tighten the 9 bolts in several steps, and then tighten them to the specified torque.

Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)

Fig 49: Tightening Bolts