Disassembly [09/2015 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.

REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT

Remove the 4 transfer and transaxle setting stud bolts from the transfer case sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE NO. 2 TRANSFER CASE PLUG

Remove the No. 2 transfer case plug from the transfer case sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the gasket from the No. 2 transfer case plug.

REMOVE FILLER PLUG (NO. 1 TRANSFER CASE PLUG)

Remove the filler plug (No. 1 transfer case plug) from the transfer case sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the gasket from the filler plug (No. 1 transfer case plug).

REMOVE TRANSFER DRAIN PLUG

Remove the transfer drain plug from the transfer case sub-assembly.

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Remove the gasket from the transfer drain plug.

REMOVE TRANSFER CASE BREATHER PLUG

Using a chisel and hammer, lift the transfer case breather plug slightly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a screwdriver, remove the transfer case breather plug from the transfer case cover sub-assembly.

REMOVE TRANSFER CASE COVER SUB-ASSEMBLY

Remove the 8 bolts from the transfer case cover sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a brass bar and a hammer, remove the transfer case cover sub-assembly from the transfer case sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Rib
*b	Brass Bar

NOTE:

Place the brass bar on the rib protruding from the transfer case cover sub-assembly.

REMOVE BREATHER OIL DEFLECTOR

Remove the bolt and breather oil deflector from the transfer case cover sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE TRANSFER CASE STRAIGHT PIN

Remove the 4 transfer case straight pins from the transfer case sub-assembly.

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SECURE TRANSFER ASSEMBLY
1. Attach the transfer assembly to the overhaul attachment.

REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR

HINT:

Only perform this procedure when replacement of the transfer extension housing dust deflector or transfer extension housing sub-assembly is necessary.

Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Transfer Extension Housing Type T Oil Seal

SST: 09308-00010

NOTE:

Be careful not to damage the transfer extension housing type T oil seal contact surface or the inside surface of the transfer extension housing type T oil seal.

REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY

Remove the 4 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PRELOAD
See step 1
INSPECT RING GEAR BACKLASH
See step 2
INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION
See step 3

REMOVE TRANSFER CASE OIL SEAL

Using SST, remove the transfer case oil seal from the transfer case sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Transfer Case Oil Seal

SST: 09308-00010

NOTE:

Do not damage the transfer case oil seal contact surface to the transfer case sub-assembly.
Wear or damage to the front drive shaft oil seal RH (for Inside) on the transmission side will cause transfer oil leakage.
If it is worn or damaged, replace the front drive shaft oil seal RH (for Inside).

Refer to REPLACEMENT [09/2015 - 08/2016] , or refer to REPLACEMENT [08/2016 - 08/2019] , or refer to REPLACEMENT [08/2019 - ]

REMOVE TRANSFER CASE OIL SEAL RH

Using SST, remove the transfer case oil seal RH from the transfer case sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Transfer Case Oil Seal RH

SST: 09308-00010

NOTE:

Do not damage the transfer case oil seal RH contact surface to the transfer case sub-assembly.

REMOVE BEARING CAP

Remove the 2 bolts and bearing cap from the transfer case sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER

Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer from the transfer case sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Transfer Output Shaft Spacer
*a	Screwdriver
*b	Piece of Cloth

SST: 09504-22012

NOTE:

Do not damage the transfer case sub-assembly.

REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER
1. Remove the No. 2 transfer ring gear mounting case washer from the transfer case sub-assembly.

REMOVE TRANSFER RING GEAR MOUNTING CASE

Remove the transfer ring gear mounting case from the transfer case sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE DRIVEN PINION

Using SST and a hammer, unstake the gear nut.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09930-00010

HINT:

Use SST with the flat side facing outward.
Do not machine the tip of SST with a grinder, etc.

Using SST, remove the gear nut.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Turn
*b	Hold

SST: 09326-20011
SST: 09556-16030

Using a press, press out the driven pinion, rear transfer driven pinion bearing (inner race) and transfer pinion bearing spacer.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Rear Transfer Driven Pinion Bearing (inner race)
*2	Transfer Pinion Bearing Spacer
*3	Driven Pinion

NOTE:

Place a piece of cloth under the transfer case sub-assembly to prevent the driven pinion from dropping out of the rear transfer driven pinion bearing (inner race).
Use wooden blocks or similar objects under the transfer case sub-assembly to keep it level.

REMOVE FRONT TRANSFER DRIVEN PINION BEARING

Using SST and a press, remove the front transfer driven pinion bearing (inner race) from the driven pinion.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09950-00020

NOTE:

Make sure to keep the outer race of the front transfer driven pinion bearing (inner race) from being applied force as shown the illustration.
Do not deform the cage of the front transfer driven pinion bearing (inner race) (when reusing the front transfer driven pinion bearing (inner race)).

Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the front transfer driven pinion bearing (outer race) to remove it from the transfer case sub-assembly.

NOTE:

Fit the brass bar to the 2 cutouts of the transfer case sub-assembly.

REMOVE TRANSFER OUTPUT SHAFT WASHER
1. Remove the transfer output shaft washer from the transfer case sub-assembly.
  NOTE:
  If the transfer output shaft washer is damaged or deformed, replace it with a new one.

REMOVE RING GEAR MOUNTING CASE BEARING

for RH side:

Remove the ring gear mounting case bearing (outer race) from the transfer ring gear mounting case.

Using SST, remove the ring gear mounting case bearing (inner race) from the transfer ring gear mounting case.

*a	Turn
*b	Hold

SST: 09950-40011
1. 09951-04010
2. 09952-04010
3. 09953-04020
4. 09954-04010
5. 09955-04061
6. 09957-04010
7. 09958-04011
SST: 09950-60010
1. 09951-00440

NOTE:

Use SST (09953-04020) after applying grease to its threads and tip.
Do not deform the cage of the ring gear mounting case bearing (inner race) (when reusing the ring gear mounting case bearing (inner race)).
Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the ring gear mounting case bearings).

for LH side:

Using SST, remove the ring gear mounting case bearing (inner race) from the transfer ring gear mounting case.

*a	Turn
*b	Hold

SST: 09950-40011
1. 09951-04010
2. 09952-04010
3. 09953-04020
4. 09954-04010
5. 09955-04061
6. 09957-04010
7. 09958-04011
SST: 09950-60010
1. 09951-00400

NOTE:

Use SST (09953-04020) after applying grease to its threads and tip.
Do not deform the cage of the ring gear mounting case bearing (inner race) (when reusing the ring gear mounting case bearing (inner race)).
Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the ring gear mounting case bearings).

Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the ring gear mounting case bearing (outer race) to remove it from the transfer case sub-assembly.

NOTE:

Fit the brass bar to the 2 cutouts of the transfer case sub-assembly.

Remove the ring gear mounting case plate washer from the transfer case sub-assembly.
NOTE:
If the ring gear mounting case plate washer is damaged or deformed, replace it with a new one.

INSPECT RUNOUT OF RING GEAR
See step 4

REMOVE RING GEAR

Secure the transfer ring gear mounting case in a vise using aluminum plates.
NOTE:
Be careful not to damage the transfer ring gear mounting case in the vise.

Put matchmarks on the transfer ring gear mounting case and ring gear.

Matchmark

Remove the 12 bolts.

Using a plastic hammer, remove the ring gear from the transfer ring gear mounting case.

NOTE:

Do not damage the ring gear teeth.

INSPECT TRANSFER RING GEAR MOUNTING CASE
See step 5

REMOVE REAR TRANSFER DRIVEN PINION BEARING (OUTER RACE)

Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the rear transfer driven pinion bearing (outer race) to remove it from the transfer case sub-assembly.

NOTE:

Fit the brass bar to the 2 cutouts of the transfer case sub-assembly.