LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Lexus >> 2007 >> IS 350 >> Repair and Diagnosis >> External Pages >> Different car >> Section 19 (Transfer Case) >> Transfer Assembly >> Disassembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Transfer Assembly: Disassembly

WARNING: This page is about a different car, the 2007 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE TRANSFER OIL PAN 
    1. Remove the 9 bolts.
      Fig 1: Identifying Transfer Oil Pan Bolts
      G05295858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the blade of SST between the transfer oil pan and transfer case. Cut through the sealer and remove the transfer oil pan.

      SST 09032-00100 

      NOTE: Do not damage the contact surface of the transfer oil pan.
      Fig 2: Inserting Blade Of SST Between Transfer Oil Pan And Transfer Case
      G05295859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the transfer oil cleaner magnet from the transfer oil pan.
      NOTE:
      • Clean the inside of the oil pan thoroughly, removing all metal shavings, sludge and any other foreign objects.
      • Remove any metal shavings from the magnet.
      Fig 3: Identifying Metal Shavings From Magnet
      G05295860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE TRANSFER VALVE BODY ASSEMBLY 
    1. Remove the 4 bolts and the transfer valve body assembly.
    2. Disconnect the transfer wire connector from the transfer control solenoid.
      Fig 4: Identifying Transfer Wire Connector
      G05295861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and the transfer wire.
      Fig 5: Identifying Bolt
      G05318686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR 
    1. Using SST, remove the transfer extension housing dust deflector.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04051, 09958-04011) 

      NOTE: Apply grease to the threads and tip of the SST center bolt before use.
      Fig 6: Removing Transfer Extension Housing Dust Deflector
      G05295863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSFER CASE 
    1. Remove the 8 bolts and clamp.
      Fig 7: Identifying Transfer Case Bolts
      G05318688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, tap the transfer case to remove it.
      Fig 8: Tapping Transfer Case
      G05295865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSFER REAR OUTPUT SHAFT ASSEMBLY 
    1. Remove the transfer rear output shaft assembly.
      Fig 9: Identifying Transfer Rear Output Shaft
      G05295866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FLANGE YOKE 
    1. Using SST and a hammer, release the staked part of the nut.

      SST 09930-00010 

      NOTE:
      • Be sure to use the SST with the tapered surface facing the shaft.
      • Do not grind the tip of the SST with a grinder etc.
      • Completely loosen the staked part of the nut when removing it.
      • Do not damage the threads of the transfer drive sprocket.
        Fig 10: Releasing Flange Yoke Nut Using SST And Hammer
        G05295867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, hold the yoke.

      SST 09330-00021, 09213-54015 

    3. Using a deep socket wrench (30 mm), remove the nut.
    4. Remove the flange yoke.
      Fig 11: Removing Flange Nut
      G05318692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE REAR TRANSFER CHAIN CASE 
    1. Remove the 10 bolts.
      Fig 12: Identifying Rear Transfer Chain Case Bolts
      G05295869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tap the 3 protrusions of the transfer chain case gently with a brass bar and hammer to loosen, and remove it.
      NOTE: Do not damage the transfer chain case.
      Fig 13: Identifying Protrusions Of Transfer Chain Case
      G05318694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSFER FRONT DRIVE CHAIN 
    1. Remove the transfer front drive chain, transfer drive sprocket and transfer front driven clutch sleeve.
    2. Remove the transfer front drive chain from the transfer drive sprocket and transfer front driven clutch sleeve.
      Fig 14: Identifying Transfer Front Drive Chain
      G05295871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT TRANSFER CHAIN CASE 
    1. Remove the 6 bolts and front transfer chain case.

      HINT:

      If necessary, tap the transfer chain case front with a plastic hammer to loosen and remove it.

      Fig 15: Identifying Front Transfer Chain Case With Bolts
      G05295872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE TRANSFER CASE REAR OIL SEAL 
    1. Using a screwdriver with its tip taped, pry out the oil seal from the transfer case.
      Fig 16: Prying Out Oil Seal From Transfer Case Using Screwdriver
      G05295873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and clamp.
      Fig 17: Identifying Transfer Case Clamp With Bolt
      G05295874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSFER CASE BEARING 
    1. Using SST, remove the transfer case bearing from the transfer case.

      SST 09308-00010 

      Fig 18: Removing Transfer Case Bearing Using SST
      G05295875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE TRANSFER BAFFLE VALVE SUB-ASSEMBLY 
    1. Remove the bolt and transfer baffle valve from the rear transfer chain case.
      Fig 19: Identifying Transfer Baffle Valve Sub-Assembly
      G05295876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSFER CHAIN CASE GOVERNOR APPLY GASKET 
    1. Remove the screw, O-ring, and 2 gaskets from the front transfer chain case.
      Fig 20: Identifying Gaskets And Screw To Transfer Chain Case
      G05295877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 gaskets from the rear transfer chain case.
      Fig 21: Identifying Rear Transfer Chain Case Gaskets
      G05295878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE TRANSFER CASE FRONT OIL SEAL 
    1. Using a screwdriver with its tip taped, pry out the oil seal from the transfer chain case front.
      Fig 22: Removing Transfer Case Front Oil Seal Using Screwdriver
      G05295879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE CENTER DIFFERENTIAL CARRIER ASSEMBLY 
    1. Remove the center differential carrier from the transfer rear output shaft and transfer direct clutch drum.
      Fig 23: Identifying Center Differential Carrier
      G05295880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE TRANSFER REAR OUTPUT SHAFT BEARING 
    1. Remove the transfer rear output shaft bearing from the transfer direct clutch drum.
  17. INSPECT CENTER DIFFERENTIAL CARRIER ASSEMBLY (See  INSPECTION   ) 
    Fig 24: Identifying Transfer Rear Output Shaft Bearing
    G05295881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE CENTER DIFFERENTIAL CLUTCH DISC SET 
    1. Using a screwdriver with its tip taped, remove the snap ring from the transfer direct clutch drum.
      Fig 25: Removing Snap Ring Using Screwdriver
      G05295883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 center differential clutch disc flanges and center differential clutch disc set from the transfer direct clutch drum.

      HINT:

      • A: Center differential clutch disc flange (No. 1)
      • B: Center differential clutch disc set (Discs)
      • C: Center differential clutch disc set (Plates)
      • D: Center differential clutch disc flange (No. 2)
  19. INSPECT CENTER DIFFERENTIAL CLUTCH DISC SET (See  INSPECTION   ) 
    Fig 26: Identifying Center Differential Clutch Disc Flanges And Center Differential Clutch Disc Set
    G05295884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER 
    1. Place SST on the center differential clutch pressure balancer, and compress the return spring with a press.

      SST 09350-30020 (09350-07040) 

    2. Using SST, remove the snap ring.

      SST 09350-30020 (09350-07040, 09350-07070) 

      Fig 27: Compressing Return Spring Using SST
      G05295886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the center differential clutch pressure balancer from the transfer direct clutch drum.
      Fig 28: Identifying Center Differential Clutch Pressure Balancer
      G05295887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY 
    1. Remove the transfer direct clutch return spring from the transfer direct clutch drum.
  22. INSPECT TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY (See  INSPECTION   ) 
    Fig 29: Identifying Transfer Direct Clutch Return Spring
    G05295888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE CENTER DIFFERENTIAL CLUTCH PISTON 
    1. Install the transfer direct clutch drum to the transfer center support.
      Fig 30: Identifying Transfer Direct Clutch Drum To Transfer Center Support
      G05295890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. While pushing down evenly on the center differential clutch piston, apply air (200 kpa, 2.0 kgf*cm2 , 19 psi) into the oil hole on the transfer chain case rear as shown in the illustration to remove the center differential clutch piston from the transfer direct clutch drum.
    3. Remove the direct clutch drum from the transfer center support.
      Fig 31: Applying Air At Oil Hole On Transfer Chain Case Rear
      G05295891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSFER DIRECT CLUTCH PISTON O-RING 
    1. Remove the 2 O-rings from the center differential clutch piston.
  25. INSPECT TRANSFER DIRECT CLUTCH DRUM (See  INSPECTION   ) 
    Fig 32: Identifying Transfer Direct Clutch Piston O-Ring
    G05295892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE TRANSFER CENTER SUPPORT 
    1. Remove the 5 bolts and transfer center support.
    2. Remove the 2 screws and 2 O-rings from the rear transfer chain case.
      Fig 33: Identifying Transfer Center Support With Bolts
      G05295894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE TRANSFER CENTER SUPPORT SEAL RING 
    1. Remove the 2 transfer center support seal rings from the transfer center support.
  28. INSPECT TRANSFER CENTER SUPPORT (See  INSPECTION   ) 
    Fig 34: Identifying Transfer Center Support Seal Rings
    G05295895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    1. Using SST and a press, remove the transfer driven sprocket bearing from the transfer front driven clutch sleeve.

      SST 09950-00020 

      Fig 35: Removing Transfer Driven Sprocket Bearing From Transfer Front Driven Clutch Sleeve Using SST
      G05295897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the transfer driven sprocket bearing from the transfer front driven clutch sleeve.

      SST 09950-60010 (09951-00530), 09950-70010 (09951-07100) 

      Fig 36: Removing Transfer Driven Sprocket Bearing From Transfer Front Driven Clutch Sleeve Using SST
      G05295898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE TRANSFER DRIVE SPROCKET BEARING 
    1. Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket.

      SST 09950-00020, 09950-70010 (09951-07100), 09950-60010 (09951-00480) 

      Fig 37: Removing Transfer Drive Sprocket Bearing From Transfer Drive Sprocket Using SST
      G05295899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket.

      SST 09950-00020, 09950-70010 (09951-07100), 09950-60010 (09951-00550) 

      Fig 38: Removing Transfer Drive Sprocket Bearing From Transfer Drive Sprocket Using SST
      G05295900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE TRANSFER CONTROL SOLENOID 
    1. Remove the bolt, solenoid lock plate and transfer control solenoid.
      Fig 39: Identifying Transfer Control Solenoid And Solenoid Lock Plate
      G05318720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TRANSFER VALVE BODY COVER 
    1. Remove the 6 bolts.
      Fig 40: Identifying Transfer Valve Body Cover Bolts
      G05318721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the transfer valve body cover and upper transfer valve body plate from the transfer upper valve body.
    3. Remove the solenoid oil strainer from the transfer valve body cover.
      Fig 41: Identifying Transfer Valve Body Cover And Upper Transfer Valve Body Plate
      G05318722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE TRANSFER SOLENOID MODULATOR VALVE 
    1. While pushing on the transfer modulator valve plug, remove the transfer solenoid modulator valve plug seat from the transfer upper valve body.
      Fig 42: Identifying Transfer Solenoid Modulator Valve Plug Seat
      G05318723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the transfer solenoid modulator valve plug, transfer solenoid modulator valve and low-high shift valve compression spring from the transfer upper valve body.
      Fig 43: Identifying Low-High Shift Valve Compression Spring, Transfer Solenoid Modulator Valve And Valve Plug
      G05295905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE CENTER DIFFERENTIAL CLUTCH CONTROL VALVE 
    1. While pushing on the center differential clutch control valve plug, remove the center differential clutch control valve plug seat from the transfer upper valve body.
      Fig 44: Identifying Center Differential Clutch Control Valve Seat
      G05318725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the center differential clutch control valve plug, center differential clutch control valve, transfer direct clutch modulator valve spring and center differential clutch control valve sleeve from the transfer upper valve body.
      Fig 45: Identifying Center Differential Clutch Control Valve
      G05295907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals