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Transfer Assembly: Disassembly

  1. REMOVE BREATHER HOSE 
  2. REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR 
    1. Remove the bolt and driven gear.
  3. REMOVE MOTOR ACTUATOR 
    1. Remove the 4 bolts and motor actuator.
    Fig 1: Identifying Motor Actuator
    G04063080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE OUTPUT GEAR 
    Fig 2: Identifying Output Gear
    G04063081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE SCREW PLUG 
    1. Using a T40 "torx" socket, remove the screw plug.
    Fig 3: Identifying Screw Plug
    G04063082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE SPRING 
    1. Using a magnetic finger, remove the spring.
  7. REMOVE BALL 
    1. Using a magnetic finger, remove the ball.
  8. REMOVE TRANSFER INDICATOR SWITCH 
    1. Remove the 3 indicator switches and 3 gaskets.
  9. REMOVE FRONT TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 6 bolts and extension housing.
    Fig 4: Identifying Front Transfer Extension Housing
    G04063083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

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

  10. REMOVE CLUTCH SLEEVE WITH NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK 
    Fig 5: Identifying Clutch Sleeve And No 2 Shift Fork
    G04063084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. SEPARATE NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK 
    1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the No. 2 shift fork shaft.
      Fig 6: Identifying Snap Rings
      G04063085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the No. 2 shift fork shaft and No. 2 shift fork.
  12. REMOVE REAR TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 9 bolts and extension housing.
    Fig 7: Identifying Rear Transfer Extension Housing
    G04063086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

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

  13. REMOVE ADJUSTING SHIM 
    1. Remove the adjusting shims.
  14. REMOVE OIL STRAINER ASSEMBLY 
    1. Remove the 2 bolts and oil strainer.
    Fig 8: Identifying Oil Strainer Assembly
    G04063087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE CASE COVER 
    1. Remove the 5 bolts.
      Fig 9: Identifying Bolts
      G04063088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and hammer, tap the case cover and remove it.
    Fig 10: Identifying Case Cover
    G04063089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. 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
      G04063090Courtesy 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: Identifying Rear Case
    G04063091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE BEARING RACE 
    1. Remove the 2 bearing races from the rear case.
    Fig 13: Identifying Bearing Race
    G04063092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE INPUT SHAFT SUB-ASSEMBLY 
    1. Using a plastic-faced hammer, remove the input shaft from the front case.
    Fig 14: Identifying Input Shaft
    G04063093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, NO. 1 SHIFT FORK SHAFT AND NO. 1 SHIFT FORK 
    1. Remove the idler gear with center differential, No. 1 shift fork shaft and No. 1 shift fork from the front case.
    Fig 15: Identifying Idler Gear With Center Differential, No 1 Shift Fork Shaft And No 1 Shift Fork
    G04063094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. SEPARATE NO. 1 SHIFT FORK SHAFT AND NO. 1 SHIFT FORK 
    1. Using a pin punch and hammer, tap out the slotted spring pin.
      Fig 16: Identifying Spring Pin
      G04063095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the No. 1 shift fork and No. 1 shift fork shaft.
  21. REMOVE OUTER SHIFT LEVER AND INNER SHIFT LEVER 
    1. Remove the nut and washer from the outer shift lever.
    2. Using a brass bar, hammer and socket wrench, tap out the lever lock pin.
      Fig 17: Identifying Lever Lock Pin
      G04063096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the outer shift lever, washer and inner shift lever from the front case.
  22. REMOVE INNER SHIFT LEVER OIL SEAL 
    1. Using a screwdriver, pry out the oil seal from the front case.
    Fig 18: Identifying Inner Shift Lever Oil Seal
    G04063097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE INPUT SHAFT OIL SEAL 
    1. Using SST and a hammer, tap out the oil seal.
    Fig 19: Identifying Input Shaft Oil Seal
    G04063098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09316-60011 (09316-00011) 

  24. REMOVE OIL RECEIVER 
    1. Remove the bolt and oil receiver from the front case.
    Fig 20: Identifying Oil Receiver
    G04063099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE BEARING RACE 
    1. Using SST, remove the bearing race (for the idler gear).
      Fig 21: Identifying Bearing Race (For Idler Gear)
      G04063100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010), 09950-60010 (09951-00320) 

    2. Using a brass bar and hammer, tap out the bearing race (for the output shaft) from the front case.
    Fig 22: Removing Bearing Race (For Output Shaft) From Front Case
    G04063101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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