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Transfer Assembly: Reassembly: Reassembly

  1. INSTALL TRANSFER LOW PLANETARY RING GEAR 
    1. Install the low planetary ring gear to the front case.
      Fig 1: Identifying Transfer Low Planetary Ring Gear Position
      GTY154633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure to install the low planetary ring gear in the correct direction.

    2. Using a screwdriver, install the snap ring.
      Fig 2: Using Screwdriver To Install Snap Ring
      GTY154632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL HEAD PIN 
    1. Install head pin.
      Fig 3: Identifying Transfer Case Plug
      GTY141283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL COMPRESSION SPRING 
  4. INSTALL TRANSFER CASE PLUG 
    1. Apply sealant to the case plug threads.

      Sealant

      Part NO. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

    2. Install the case plug.

      Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) 

  5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER 
    1. Install the transfer output shaft plate washer.
      Fig 4: Identifying Transfer Output Shaft Plate Washer
      GTY154643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL TRANSFER DRIVE SPROCKET BEARING 
  7. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
  8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER 
  9. INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST and a press, install a new output shaft rear radial ball bearing.
      Fig 5: Installing Transfer Output Shaft Rear Radial Ball Bearing
      GTY135254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-60011 
        • 09316-00011
        • 09316-00071
      NOTE:

      Install the output shaft rear radial ball bearing so that the bearing snap ring groove face to the rear.

  10. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER 
    1. Install the transfer output shaft plate washer.
      Fig 6: Identifying Transfer Clutch Hub
      GTY154641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
  12. INSTALL TRANSFER CLUTCH HUB 
  13. INSTALL CENTER DIFFERENTIAL CASE 
    1. Install the center differential case.
      Fig 7: Using Snap Ring Expander To Install Transfer Low Planetary Ring Gear Hole Snap Ring
      GTY154673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL 
  15. INSTALL TRANSFER OUTPUT SHAFT SPACER NO. 2 
  16. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING 
    1. Using a snap ring expender, install the snap ring.
  17. INSPECT DRIVE SPROCKET RADIAL CLEARANCE  See step  5
  18. INSPECT DRIVE SPROCKET THRUST CLEARANCE  See step  4
  19. INSTALL TRANSFER INPUT SHAFT BEARING 
    1. Using SST and a press, install a new bearing with the groove facing forward.
      Fig 8: Using SST & Press To Install New Transfer Input Shaft Bearing
      GTY154653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-15020 
      • SST: 09515-30010 
      • SST: 09950-70010 
        • 09951-07100
  20. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    Fig 9: Using SST & Press To Tap In New Transfer Low Planetary Gear Bearing
    GTY156445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, tap in a new low planetary gear bearing.
      • SST: 09950-60010 
        • 09951-00570
      • SST: 09950-70010 
        • 09951-07100

      Press in depth

      7.7 to 8.3 mm (0.303 to 0.327 in.)

  21. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, install the spline piece with the snap ring.
      Fig 10: Using Screwdriver To Install Spline Piece With Snap Ring
      GTY154652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING 
    1. Select a snap ring that allows the minimum axial play.
      Fig 11: Selecting A Snap Ring
      GTY134081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Mark Thickness mm (in.)
      1 1.45 to 1.50 (0.0571 to 0.0591)
      2 1.50 to 1.55 (0.0591 to 0.0610)
      3 1.55 to 1.60 (0.0610 to 0.0630)
      4 1.60 to 1.65 (0.0630 to 0.0650)
      5 1.65 to 1.70 (0.0650 to 0.0669)
    2. Using a snap ring expander, install a new snap ring.
  23. INSTALL TRANSFER NO. 1 INPUT SHAFT SEAL RING 
    1. Apply gear oil to the 2 new oil seal rings.
      Fig 12: Identifying Transfer No. 1 Input Shaft Seal Ring Clearance
      GTY134078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage securely to eliminate clearance as shown in the illustration.
  24. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    NOTE:

    Make sure to install the transfer low planetary gear bearing in the correct direction.

    1. Install the transfer low planetary gear bearing.
      Fig 13: Identifying Transfer Low Planetary Gear Bearing
      GTY141162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL NO. 1 TRANSFER THRUST BEARING RACE 
  26. INSTALL TRANSFER INPUT SHAFT 
  27. INSTALL MANUAL TRANSFER PLANETARY CARR WASHER 
    1. Install the manual transfer planetary carrier washer.
      Fig 14: Identifying Manual Transfer Planetary Carrier Washer
      GTY154631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL TRANSFER INPUT GEAR STOPPER BALL 
  29. INSTALL TRANSFER INPUT GEAR STOPPER 
  30. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    1. Select an input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) axial play.
      Fig 15: Checking Transfer Input Gear Stopper Shaft Snap Ring
      GTY154654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Mark Thickness mm (in.)
      A 2.10 to 2.15 (0.0827 to 0.0846)
      B 2.15 to 2.20 (0.0846 to 0.0866)
      C 2.20 to 2.25 (0.0866 to 0.0886)
      D 2.25 to 2.30 (0.0886 to 0.0906)
      E 2.30 to 2.35 (0.0906 to 0.0925)
      F 2.35 to 2.40 (0.0925 to 0.0945)
      G 2.40 to 2.45 (0.0945 to 0.0965)
      H 2.45 to 2.50 (0.0965 to 0.0984)
      J 2.50 to 2.55 (0.0984 to 0.1004)
      K 2.55 to 2.60 (0.1004 to 0.1024)
      L 2.60 to 2.65 (0.1024 to 0.1043)
      M 2.65 to 2.70 (0.1043 to 0.1063)
      N 2.70 to 2.75 (0.1063 to 0.1083)
      P 2.75 to 2.80 (0.1083 to 0.1102)
      Q 2.80 to 2.85 (0.1102 to 0.1122)
      R 2.85 to 2.90 (0.1122 to 0.1142)
      S 2.90 to 2.95 (0.1142 to 0.1161)
      T 2.95 to 3.00 (0.1161 to 0.1181)
      U 3.00 to 3.05 (0.1181 to 0.1201)
    2. Using a snap ring expander, install the new input gear stopper shaft snap ring.
      Fig 16: Using Snap Ring Expander To Install New Input Gear Stopper Shaft Snap Ring
      GTY136731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL TRANSFER CASE OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its metal ring contacts the case (No. 1).
      Fig 17: Installing Transfer Case Oil Seal
      GTY126984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09550-00032 
      • SST: 09950-70010 
        • 09951-07100
    2. Coat the lip of the oil seal with MP grease.
    3. Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 2).
      Fig 18: Using SST & Hammer To Install New No. 2 Transfer Case Oil Seal
      GTY123539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Oil seal drive in depth

      -0.5 to 0.5 mm (-0.020 to 0.02 in.)

    4. Coat the lip of the oil seal with MP grease.
  32. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY 
    1. Install the low planetary gear assembly with input shaft sub-assembly.
      Fig 19: Identifying Low Planetary Gear Assembly With Input Shaft Sub-Assembly
      GTY154630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If necessary, heat the front case to about 50 to 80°C (122 to 176°F).

    2. Using a snap ring expander, install the shaft snap ring.
      Fig 20: Using Snap Ring Expander To Install Shaft Snap Ring
      GTY143364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL TRANSFER OIL PUMP GEAR 
    1. Install transfer oil pump gear.
      Fig 21: Identifying Transfer Oil Pump Gear
      GTY154629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL TRANSFER OIL PUMP BODY O-RING 
    1. Coat a new O-ring with gear oil and install it to the oil pump body.
      Fig 22: Identifying Transfer Oil Pump Body O-Ring
      GTY154637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Install the oil pump body sub-assembly with the 3 bolts.
      Fig 23: Identifying Transfer Oil Pump Body Sub-Assembly Bolts
      GTY154627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  36. INSTALL TRANSFER CASE MAGNET 
    1. Install transfer case magnet.
      Fig 24: Identifying Transfer Oil Separator Sub-Assembly Bolts
      GTY154626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Install the oil separator sub-assembly with the 3 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  38. INSTALL TRANSFER CASE NO. 1 PLUG 
    1. Install the case plug No. 1 (filler plug) and a new gasket.

      Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 

  39. INSTALL TRANSFER CASE NO. 1 PLUG 
    1. Install the case plug (drain plug) and a new gasket.

      Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 

  40. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY 
    1. Install the shift actuator assembly with the 3 bolts.
      Fig 25: Identifying Transfer Shift Actuator Assembly Bolts
      GTY154625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

    2. Using a screwdriver and hammer, drive in the 2 snap rings.
  41. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING 
    1. Using SST and a press, install a new input gear radial ball bearing.
      Fig 26: Using SST & Press To Install New Input Gear Radial Ball Bearing
      GTY129294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-60011 
        • 09316-00031
  42. INSTALL TRANSFER DRIVEN SPROCKET BEARING 
    1. Using the press, install a new driven sprocket bearing.
      Fig 27: Using Press To Install New Transfer Driven Sprocket Bearing
      GTY154671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY 
    1. Install the rear output shaft sub-assembly and drive sprocket to the front drive chain.
      Fig 28: Identifying Rear Output Shaft Sub-Assembly Front Drive Chain & Driven Sprocket Sub-Assembly
      GTY154623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear output shaft sub-assembly front drive chain and driven sprocket sub-assembly to the case rear.
      Fig 29: Identifying Rear Output Shaft Sub-Assembly
      GTY134097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • Check that the rear output shaft sub-assembly and driven sprocket sub-assembly turn lightly.
      • If necessary, heat the rear case to about 50 to 80°C (122 to 176°F).
    3. Using a snap ring expander, install the snap ring.
      Fig 30: Using Snap Ring Expander To Install Snap Ring
      GTY154622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE 
    1. Install the CTR differential lock fork sub-assembly and front drive clutch sleeve.
      Fig 31: Identifying CTR Differential Lock Fork Sub-Assembly & Front Drive Clutch Sleeve With Bolt
      GTY155066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt.

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

    3. Using a screwdriver and hammer, drive in the snap ring.
      NOTE:

      Make sure to install the fork and clutch sleeve in the correct direction.

  45. INSTALL TRANSFER GEAR SHIFT FORK NO. 2 WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE 
    1. Install the gear shift fork No. 2 and high and low shift fork shaft and high and low clutch sleeve.
      Fig 32: Identifying Transfer Gear Shift Fork No. 2 Bolt
      GTY154722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure to install the fork in the correct direction.

    2. Apply sealant to the plug No. 1 threads.

      Sealant

      Part NO. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

    3. Install the spring and ball to the hole.
    4. Install the plug No. 1 to the hole.

      Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) 

    5. Using a pin punch and hammer, install the slotted pin.
  46. INSTALL TRANSFER OUTPUT SHAFT SPACER 
    1. Install the transfer output shaft spacer.
      Fig 33: Identifying Transfer Output Shaft Front Needle Roller Bearing
      GTY155118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
    1. Install the transfer output shaft front needle roller bearing.
  48. INSTALL TRANSFER REAR CASE 
    1. Apply FIPG to the case rear, as shown.
      Fig 34: Applying FIPG On Case Rear
      GTY128064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      FIPG

      Part No. 08826-00090, THREE BOND 1281 or equivalent

    2. Install the 2 clamps and case rear with the 12 bolts.
      Fig 35: Identifying Transfer Rear Case Bolts & Clamps
      GTY129981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 28 N*m (285 kgf*cm, 21 ft.*lbf) 

  49. INSTALL COLLAR 
    1. Install collar.
      Fig 36: Identifying Transfer Output Washers & Collar
      GTY122433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL TRANSFER OUTPUT SHAFT WASHER 
    1. Install 2 output washers.
  51. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST and a hammer, drive in a new oil seal until its surface is flush with the housing upper surface.
      Fig 37: Using SST & Hammer To Install New Transfer Extension Housing Type T Oil Seal
      GTY154655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-46011 
      • SST: 09631-32020 
    2. Coat the lip of the oil seal with MP grease.
  52. INSTALL EXTENSION HOUSING SUB-ASSEMBLY 
    1. Apply FIPG to the extension housing assembly rear, as shown in the illustration.
      Fig 38: Identifying FIPG On Extension Housing Assembly Rear
      GTY122600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      FIPG

      Part No. 08826-00090, THREE BOND 1281 or equivalent

    2. Apply sealant to the bolt threads.

      Sealant

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

    3. Install the extension housing assembly with the 5 bolts.
      Fig 39: Identifying Extension Housing Sub-Assembly Bolts
      GTY154620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

  53. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using SST and a hammer, drive in a new oil seal (front side).
      Fig 40: Using SST & Hammer To Install New Transfer Output Shaft Companion Flange Oil Seal
      GTY154656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        • 09951-00320
      • SST: 09950-70010 
        • 09951-07100
    2. Coat the lip of the oil seal with MP grease.
  54. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Drive in a new oil seal (rear) in the same way as the oil seal (front).
      • SST: 09950-60010 
        • 09951-00320
      • SST: 09950-70010 
        • 09951-07100
    2. Coat the lip of the oil seal with MP grease.
  55. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Install the companion flange sub-assembly (front side) onto the drive sprocket sub-assembly.
      Fig 41: Installing Companion Flange Sub-Assembly
      GTY130535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST to hold the companion flange, install a new companion flange lock nut.
      • SST: 09330-00021 

      Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf) 

    3. Using a chisel and hammer, stake the companion flange lock nut.
  56. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using SST, install the companion flange sub-assembly using the same procedure as for the companion flange sub-assembly (rear side).

      Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf) 

      • SST: 09330-00021 
  57. INSTALL BREATHER OIL DEFLECTOR 
  58. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Install the case cover sub-assembly with the 4 bolts.
      Fig 42: Identifying Transfer Case Cover Sub-Assembly Bolts
      GTY154617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 

  59. INSTALL TRANSFER COVER TYPE T OIL SEAL 
    1. Using SST and a hammer, drive in a new oil seal until its surface is flush with the retainer upper surface.
      Fig 43: Using SST & Hammer To Install New Transfer Cover Type T Oil Seal
      GTY154657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the lip of the oil seal with MP grease.
      • SST: 09950-60010 
        • 09951-00590
      • SST: 09950-70010 
        • 09951-07100
  60. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY 
    1. Apply FIPG to the front bearing retainer sub-assembly, as shown in the illustration.
      Fig 44: Identifying FIPG On Front Bearing Retainer Sub-Assembly
      GTY127393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      FIPG

      Part No. 08826-00090, THREE BOND 1281 or equivalent

    2. Apply sealant to the bolt threads.

      Sealant

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

    3. Install the front bearing retainer sub-assembly with the 5 bolts.
      Fig 45: Identifying Front Bearing Retainer Sub-Assembly Bolts
      GTY134107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf) 

  61. INSTALL TRANSFER GEAR SHIFT HEAD NO. 2 
    1. Using a pin punch and hammer, install the slotted pin to the gear shift head No. 2.
      Fig 46: Identifying Transfer Gear Shift Head No. 2 Slotted Pin
      GTY124179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL SWITCH 
    1. Install a new gasket, the indicator switches and the case No. 1 plug.
      Fig 47: Identifying Indicator Switches And Case No. 1 Plug
      GTY123373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

  63. INSTALL HOSES 
    1. Install the hose.
      Fig 48: Identifying Actuator Motor Breather Hose
      GTY155097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Place the hose that passes between the transfer rear case and the actuator motor.
      • Adjust the clamp position to prevent the excessive bent or expansion/contraction of the hose.
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