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Transfer Assembly: Disassembly

WARNING: This page is about a different car, the 2003 Toyota Sequoia. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE VEHICLE SPEED SENSOR ASSEMBLY 
    1. Remove the bolt and vehicle speed sensor assembly.
    2. Using a small screwdriver, remove the clip and vehicle speed sensor driven gear.
    3. Using a small screwdriver, remove the O-ring.

      Tape the small screwdriver tip before use.

  2. REMOVE L4 POSITION SWITCH, NEUTRAL POSITION SWITCH AND STRAIGHT SCREW PLUG WITH 3 GASKETS 
  3. REMOVE FRONT BEARING RETAINER 

    Remove the 5 bolts and front bearing retainer.

    Fig 1: Removing 5 Bolts And Front Bearing Retainer
    G02851656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: If necessary, tap the front bearing retainer with a plastic hammer to remove it.
  4. REMOVE TRANSFER UPPER COVER 

    Remove the 4 bolts, transfer upper cover and oil deflector.

  5. REMOVE FRONT COMPANION FLANGE 
    1. Using a chisel and hammer, loosen the staked part of the front companion flange lock nut.
    2. Using SST to hold the front companion flange, remove the front companion flange lock nut.
      Fig 2: Removing Front Companion Flange Lock Nut Using SST
      G02851657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09330-00021

    3. Using a SST, remove the front companion flange.
      Fig 3: Removing Front Companion Flange Using SST
      G02851658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)

  6. REMOVE REAR COMPANION FLANGE 

    Remove the rear companion flange in the same way as the front companion flange.

  7. REMOVE EXTENSION HOUSING 

    Remove the 5 bolts and extension housing.

    Fig 4: Removing 5 Bolts And Extension Housing
    G02851659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: If necessary, tap the front extension housing with a plastic hammer to remove it.
  8. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR AND OUTPUT SHAFT WASHER 
    1. Remove the vehicle speed sensor drive gear and 2 output shaft washers.
    2. Using a magnetic finger, remove the ball from the rear output shaft.
  9. REMOVE SHAFT HEAD NO. 2 
    1. Using a pin punch and hammer, tap out the slotted pin from the high and low fork shaft
      2. Fig 5: Taping Out Slotted Pin From High And Low Fork Shaft
      G02851660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the shaft head No. 2.
  10. REMOVE REAR CASE 

    Remove the 12 bolts, 2 clamps and rear case.

    Fig 6: Removing 12 Bolts, 2 Clamps And Rear Case
    G02851661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: If necessary, tap the rear case with a plastic hammer to remove it.
  11. REMOVE STRAIGHT SCREW PLUG, SPRING AND BALL 
    1. Using a hexagon wrench, remove the 2 straight screw plugs.
    2. Using a magnetic finger, remove the spring and ball.
      Fig 7: Removing Spring And Ball Using A Magnetic Finger
      G02851662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 2 GEAR SHIFT FORK AND HIGH AND LOW SHIFT FORK SHAFT 
    1. Remove 2 screwdrivers and a hammer, tap out the snap ring.
      Fig 8: Taping Out Snap Ring
      G02851663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, tap out the slotted spring pin from the No. 2 rear shift fork.
      Fig 9: Taping Out Slotted Spring Pin From No. 2 Rear Shift Fork
      G02851664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 2 gear shift fork and high and low shift fork shaft.
      Fig 10: Removing Gear Shift Fork And High And Low Shift Fork Shaft
      G02851665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE GEAR SHIFT FORK SHAFT 
    1. Using 2 screwdrivers and a hammer, remove the 3 snap rings from the gear shift fork shaft.
      Fig 11: Removing Snap Rings From Gear Shift Fork Shaft Using 2 Screwdrivers And Hammer
      G02851666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a hexagon wrench, remove the 2 straight screw plugs, springs and balls from the No. 1 gear shift fork and center diff. lock fork.
      Fig 12: Removing Straight Screw Plugs, Springs And Balls From No. 1 Gear Shift Fork And Center Diff. Lock Fork
      G02851667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and shift shaft stopper.
      Fig 13: Removing Bolt And Shift Shaft Stopper
      G02851668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Rotate the slit portion of the gear shift fork shaft to the No. 2 shift interlock pin and remove it.
      Fig 14: Removing Shift Interlock Pin
      G02851669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a magnetic finger, remove the 2 No. 2 shift interlock pins from the No. 1 gear shift fork and center diff. lock fork.
      Fig 15: Removing 2 No. 2 Shift Interlock Pins From No. 1 Gear Shift Fork And Center Diff. Lock Fork
      G02851670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. REMOVE REAR OUTPUT SHAFT ASSEMBLY, NO. 1 GEAR SHIFT FORK, CENTER DIFF. LOCK FORK, DRIVEN SPROCKET ASSEMBLY AND FRONT DRIVE CHAIN 
      1. Using 2 screwdrivers and a hammer, tap out the 2 snap rings from the gear shift fork shaft of the actuator assembly.
      2. Using a snap ring expander, remove the output shaft snap ring.
        Fig 16: Taping Out Snap Rings From Gear Shift Fork Shaft Of Actuator Assembly
        G02851671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Mount the rear case in a vise, as shown.
      4. Using the plastic hammer, carefully tap the case, and remove the rear output shaft assembly with the No. 1 gear shift fork, center diff. lock fork, driven sprocket assembly and front drive chain.
        Fig 17: Removing Rear Output Shaft Assembly With No. 1 Gear Shift Fork
        G02851672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Remove the front driven chain, driven sprocket assembly, center diff. lock fork and No. 1 gear shift fork from the rear output shaft assembly.
    7. REMOVE ACTUATOR ASSEMBLY 
      1. Remove the 3 bolts, clamp and actuator assembly.
      2. Remove the O-ring, No. 1 and No. 2 4WD position switches with the 2 gaskets from the actuator assembly.
        Fig 18: Removing Actuator Assembly
        G02851673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. REMOVE OIL SEPARATOR AND MAGNET 
      1. Remove the 3 bolts and oil separator.
      2. Remove the magnet from the front case.
    9. REMOVE OIL PUMP BODY ASSEMBLY 

      Remove the 3 bolts and oil pump body assembly.

      Fig 19: Removing Oil Separator And Magnet
      G02851674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. REMOVE OIL PUMP GEAR FROM FRONT CASE 
      Fig 20: Removing Oil Pump Gear From Front Case
      G02851675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY 
      1. Using a snap ring expander, remove the low planetary gear bearing snap ring.
      2. Pull out the planetary gear assembly with the input shaft assembly.
        Fig 21: Removing Low Planetary Gear Assembly With Input Shaft Assembly
        G02851676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. REMOVE LOW PLANETARY GEAR SPLINE PIECE 
      1. Using a screwdriver, remove the low planetary gear snap ring.
      2. Remove the low planetary gear spline piece.
        Fig 22: Removing Low Planetary Gear Spline Piece
        G02851677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. REMOVE OUTPUT SHAFT NEEDLE ROLLER BEARING FROM INPUT SHAFT 
      Fig 23: Removing Output Shaft Needle Roller Bearing From Input Shaft
      G02851678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. REMOVE INPUT GEAR STOPPER, LOW PLANETARY CARRIER THRUST WASHER AND INPUT GEAR STOPPER BALL 
      1. Using a snap ring expander, remove the input gear stopper snap ring.
      2. Remove the input gear stopper, low planetary carrier thrust washer and input gear stopper ball.
        Fig 24: Removing Input Gear Stopper, Low Planetary Carrier Thrust Washer And Input Gear Stopper Ball
        G02851679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. REMOVE INPUT SHAFT ASSEMBLY, LOW PLANETARY GEAR BEARING AND NO. 2 THRUST BEARING RACE 
      Fig 25: Removing Input Shaft Assembly, Low Planetary Gear Bearing And No. 2 Thrust Bearing Race
      G02851680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    16. REMOVE OIL PLANETARY RING GEAR 
      1. Using a screwdriver, remove the low planetary ring gear hole snap ring.
      2. Remove the head screw plug, spring and pin.
        Fig 26: Removing Oil Planetary Ring Gear
        G02851681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the low planetary ring gear.
        Fig 27: Removing Low Planetary Ring Gear
        G02851682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. INSPECT SWITCH 

      Check that there is continuity between terminals, as shown.

      SWITCH SPECIFIED CONDITION

      Switch Position Specified Condition
      Push Continuity
      Free No Continuity

      If operation is not as specified, replace the switch.

      Fig 28: Checking Continuity Between Terminals
      G02851683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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