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Transfer Unit: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE TRANSFER COVER GASKET 
    1. Remove the transfer gasket from the transfer assembly.
      Fig 1: Identifying Transfer Cover Gasket
      G05241019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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: Using Screwdriver & Hammer To Remove Transfer Case Breather Plug
      G05241020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the contact surface of No. 1 case cover.
  3. REMOVE NO. 1 TRANSFER CASE COVER 
    1. Remove the 8 bolts.
      Fig 3: Identifying No. 1 Transfer Case Cover Bolts
      G05241021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the No. 1 transfer case cover from the transfer base.
      NOTE: Be careful not to damage the contact surfaces of the case and cover.
  4. REMOVE BREATHER OIL DEFLECTOR 
    1. Remove the bolt and breather oil deflector from the No. 1 transfer case cover.
      Fig 4: Identifying Breather Oil Deflector Bolt
      G05241023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSFER DYNAMIC DAMPER 
    1. Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing sub-assembly.
      Fig 5: Identifying Transfer Dynamic Damper Bolts
      G05241024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 4 transfer case straight pins from the transfer case.
  7. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. Remove the 4 transfer and transaxle setting stud bolts.
  8. FIX TRANSFER ASSEMBLY 
    1. Fix the transfer assembly to the overhaul attachment.
  9. 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: Using Plastic Hammer To Remove Transfer Extension Housing Dust Deflector
      G05241025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. 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.

      SST 09308-00010 

      Fig 7: Using SST(s) To Remove Transfer Extension Housing Type T Oil Seal
      G05241026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.
  11. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 4 bolts.
      Fig 8: Identifying Bolts
      G05241027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case.
      Fig 9: Using Plastic Hammer To Remove Transfer Extension Housing Sub-Assembly
      G05241028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. 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.

      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.)

      Fig 10: Checking Driven Pinion Preload Using SST(s) & Torque Wrench
      G05241029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE CTR DIFFERENTIAL LOCK SLEEVE 
    1. Using snap ring pliers, remove the shaft snap ring.
      Fig 11: Using Snap Ring Pliers To Remove Shaft Snap Ring
      G05241030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST(s), remove the CTR differential lock sleeve.

      SST 09308-00010 

      Fig 12: Using SST(s) To Remove CTR Differential Lock Sleeve
      G05241031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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: Using Screwdriver To Remove O-Ring
      G05241032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the lock sleeve's groove for the O-ring.
  15. REMOVE TRANSFER CASE OIL SEAL 
    1. Using SST(s), remove the transfer case oil seal from the case.

      SST 09308-00010 

      Fig 14: Using SST(s) To Remove Transfer Case Oil Seal
      G05269334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the oil-seal-fitted surface of the case.
  16. 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: Using SST(s) To Remove Transfer RH Bearing Retainer Oil Seal
      G05269335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the oil-seal-fitted surface of the retainer.
  17. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY 
    1. Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.
      Fig 16: Identifying Transfer RH Bearing Retainer Sub-Assembly Bolts
      G05241035Courtesy 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.
      Fig 17: Creating Clearance Between Transfer RH Bearing Retainer Sub-Assembly & Transfer Case
      G05269337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the transfer RH bearing retainer sub-assembly and the transfer case.
    3. Using SST(s), remove the transfer RH bearing retainer sub-assembly from the transfer case.

      SST 09520-10021 

      Fig 18: Using SST(s) To Remove Transfer RH Bearing Retainer Sub-Assembly From Transfer Case
      G05269338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. 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: Identifying Transfer RH Bearing Retainer Sub-Assembly O-Rings
      G05241038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the retainer's grooves for the O-rings.
  19. 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.

      SST 09308-00010 

      Fig 20: Using SST(s) To Remove Center Differential Case Tapered Roller Bearing RH Outer Race
      G05241039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer sub-assembly.
  20. REMOVE SIDE GEAR SHAFT HOLDER BEARING 
    1. Using snap ring pliers, remove the side gear shaft holder hole snap ring.
      Fig 21: Using Snap Ring Pliers To Remove Side Gear Shaft Holder Hole Snap Ring
      G05241040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assembly.
  21. REMOVE TRANSFER RING GEAR MOUNTING CASE 
    1. Remove the transfer ring gear mounting case from the transfer case.
      Fig 22: Identifying Transfer Ring Gear Mounting Case
      G04831503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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: Attaching SST To Inner Race Of Center Differential Case Tapered Roller Bearing
      G05241042Courtesy 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: Identifying Roller & Inner Races Of Center Differential Case Tapered Roller Bearing
      G05269344Courtesy 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: Using SST(s) To Remove Inner Race Of Center Differential Case Tapered Roller Bearing
      G05241044Courtesy 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.
      NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
      Fig 26: Removing Center Differential Case Tapered Roller Bearing
      G05241045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE RING GEAR 
    1. Put matchmarks on the transfer ring gear mounting case and the ring gear.
    2. Remove the 12 bolts.
      Fig 27: Identifying Matchmarks On Transfer Ring Gear Mounting Case & Ring Gear
      G05139129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, remove the ring gear by tapping around its periphery.
      Fig 28: Using Plastic Hammer To Remove Ring Gear
      G05269348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not damage the teeth of the ring gear.
  24. REMOVE TRANSFER GEAR NUT 
    1. Using SST(s) and a hammer, unstake the transfer gear nut.

      SST 09930-00010 

      Fig 29: Using SST(s) & Hammer To Unstake Transfer Gear Nut
      G05241048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST(s), remove the transfer gear nut.
      Fig 30: Using SST(s) To Remove Transfer Gear Nut
      G05241049Courtesy 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: Using Press To Remove Driven Pinion, Transfer Driven Pinion Rear Bearing Inner Race & Transfer Pinion Bearing Spacer
      G05241050Courtesy 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.
  25. 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: Using SST(s) & Press To Remove Transfer Driven Pinion Front Bearing Inner Race
      G05241051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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.
      Fig 33: Using Brass Bar & Hammer To Remove Transfer Driven Pinion Front Bearing Outer Race
      G05241053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE RING GEAR MOUNTING CASE PLATE WASHER 
    1. Remove the transfer output washer from the transfer case.
  28. 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.
      Fig 34: Using Brass Bar & Hammer To Remove Center Differential Case Tapered Roller Bearing LH Outer Race
      G05241052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE RING GEAR MOUNTING CASE PLATE WASHER 
    1. Remove the ring gear mounting case plate washer from the transfer case.
  30. 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: Using Brass Bar & Hammer To Remove Transfer Driven Pinion Rear Bearing Outer Race
      G05241054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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