Transfer Unit: Disassembly

REMOVE TRANSFER COVER GASKET
1. Remove the transfer gasket from the transfer assembly.
Fig 1: Removing Transfer Gasket From Transfer Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE BREATHER PLUG
1. Using a screwdriver and a hammer, remove the transfer case breather plug from the No. 1 transfer case cover.
Fig 2: Removing Transfer Case Breather Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Be careful not to damage the contact surface of No. 1 case cover.
REMOVE NO. 1 TRANSFER CASE COVER
1. Remove the 8 bolts.
2. Using a brass bar and a hammer, remove the No. 1 transfer case cover from the transfer case.
Fig 3: Removing No 1 Transfer Case Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Be careful not to damage the contact surfaces of the case and cover.
REMOVE BREATHER OIL DEFLECTOR
1. Remove the bolt and breather oil deflector from the No. 1 transfer case cover.
Fig 4: Removing Breather Oil Deflector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DYNAMIC DAMPER
1. Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing subassembly.
Fig 5: Removing Transfer Dynamic Damper
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REMOVE TRANSFER CASE STRAIGHT PIN
1. Remove the 4 transfer case straight pins from the transfer case.
REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT
1. Remove the 4 transfer and transaxle setting stud bolts.
FIX TRANSFER ASSEMBLY
1. Fix the transfer assembly to the overhaul attachment.
REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR
1. Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.
Fig 6: Removing Transfer Extension Housing Dust Deflector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
1. Using SST(s), remove the transfer extension housing type T oil seal from the transfer extension housing.
Fig 7: Removing Transfer Extension Housing Type T Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09308-00010

NOTE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.
REMOVE TRANSFER EXTENSION HOUSING SUBASSEMBLY
1. Remove the 4 bolts.
  
  Fig 8: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case.
Fig 9: Removing Transfer Extension Housing Subassembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PRELOAD
1. Using SST(s) and a torque wrench, check the initial torque with the backlash range.
  SST 09326-20011
  
  Torque:
  
  0.9 to 1.4 N.m (9 to 14 kgf.cm, 8.0 to 12.4 in. lbf)
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
2. Using SST(s) and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.
Fig 10: Checking Initial Torque With Backlash Range
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09326-20011

Torque:

Preload + 0.15 to 0.30 N.m (+ 1.6 to 3.1 kgf.cm, + 1.3 to 2.7 in. lbf)

HINT:

Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
REMOVE CTR DIFFERENTIAL LOCK SLEEVE
1. Using snap ring pliers, remove the shaft snap ring.
  
  Fig 11: Removing Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST(s), remove the CTR differential lock sleeve.
Fig 12: Removing CTR Differential Lock Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09308-00010
REMOVE O-RING
1. Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.
Fig 13: Removing O-Ring From CTR Differential Lock Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Be careful not to damage the lock sleeve's groove for the O-ring.
REMOVE TRANSFER CASE OIL SEAL
1. Using SST(s), remove the transfer case oil seal from the case.
SST 09308-00010

NOTE: Be careful not to damage the oil-seal-fitted surface of the case.

Fig 14: Removing Transfer Case Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER RH BEARING RETAINER OIL SEAL
1. Using SST(s), remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.
SST 09308-00010

Fig 15: Removing Transfer RH Bearing Retainer Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Be careful not to damage the oil-seal-fitted surface of the retainer.
REMOVE TRANSFER RH BEARING RETAINER SUBASSEMBLY
1. Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.
  
  Fig 16: Removing Bolts From Transfer RH Bearing Retainer Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver and a hammer, create a clearance between the transfer RH bearing retainer sub-assembly and the transfer case.
  NOTE: Be careful not to damage the transfer RH bearing retainer sub-assembly and the transfer case.
  
  Fig 17: Creating Clearance Between Transfer RH Bearing Retainer Sub-Assembly And Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST(s), remove the transfer RH bearing retainer sub-assembly from the transfer case.
SST 09520-10021

Fig 18: Removing Transfer RH Bearing Retainer Sub-Assembly From Transfer Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE O-RING
1. Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assembly.
Fig 19: Removing O-Rings From Transfer RH Bearing Retainer Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Be careful not to damage the retainer's grooves for the O-rings.
REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Fix the transfer RH bearing retainer sub-assembly in a vise.
2. Using SST(s), remove the center differential case tapered roller bearing RH outer race, transfer ring gear mounting case washer No. 2 and right bearing retainer oil seal No. 2 from the transfer RH bearing retainer sub-assembly.
Fig 20: Removing Center Differential Case Tapered Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09308-00010

NOTE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer subassembly.
REMOVE SIDE GEAR SHAFT HOLDER BEARING
1. Using snap ring pliers, remove the side gear shaft holder hole snap ring.
2. Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assembly.
Fig 21: Removing Side Gear Shaft Holder Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER RING GEAR MOUNTING CASE
1. Remove the transfer ring gear mounting case from the transfer case.
Fig 22: Removing Transfer Ring Gear Mounting Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
  
  Fig 23: Removing Inner Race Of Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
2. When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
  
  Fig 24: Removing Roller And Remaining Inner Races Of Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
3. Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
  
  Fig 25: Removing Inner Race Of Center Differential Case Tapered Roller Bearing From Transfer Ring Gear Mounting Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
4. When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
Fig 26: Removing Roller And Remaining Inner Races Of Center Differential Case Tapered Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
REMOVE RING GEAR
1. Put matchmarks on the transfer ring gear mounting case and the ring gear.
2. Remove the 12 bolts.
  
  Fig 27: Putting Matchmarks On Transfer Ring Gear Mounting Case And Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic hammer, remove the ring gear by tapping around its periphery.
Fig 28: Removing Ring Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Do not damage the teeth of the ring gear.
REMOVE TRANSFER GEAR NUT
1. Using SST(s) and a hammer, unstake the transfer gear nut.
  
  Fig 29: Unstaking Transfer Gear Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09930-00010
2. Using SST(s), remove the transfer gear nut.
  
  Fig 30: Removing Transfer Gear Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer.
Fig 31: Removing Driven Pinion, Transfer Driven Pinion Rear Bearing Inner Race And Transfer Pinion Bearing Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- Put shop cloths around to help prevent the driven pinion from bearing dropped.
- Place something like wood blocks under the case to keep it level.
REMOVE TRANSFER DRIVEN PINION FRONT BEARING
1. Using SST(s) and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.
SST 09950-00020

Fig 32: Removing Transfer Driven Pinion Front Bearing Inner Race From Driven Pinion
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.
REMOVE RING GEAR MOUNTING CASE PLATE WASHER
1. Remove the transfer output washer from the transfer case.
Fig 33: Removing Center Differential Case Tapered Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 positions to remove it from the transfer case.
REMOVE RING GEAR MOUNTING CASE PLATE WASHER
1. Remove the ring gear mounting case plate washer from the transfer case.
Fig 34: Removing Center Differential Case Tapered Roller Bearing LH Outer Race
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVEN PINION REAR BEARING
1. Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.
Fig 35: Removing Transfer Driven Pinion Rear Bearing Outer Race
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002