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Transfer Assembly: Reassembly

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.
NOTE: Coat all of the sliding and rotating surface with gear oil before reassembly.
  1. INSTALL LOW PLANETARY RING GEAR 
    1. Install the low planetary ring gear.
      Fig 1: Installing Low Planetary Ring Gear
      G02851684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure to install the low planetary ring gear in the correct direction.
    2. Install the pin and spring.
    3. Apply sealant to the head screw plug threads.

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

    4. Install the head screw plug.

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

    5. Using a screwdriver, install the low planetary ring gear hole snap ring.
      NOTE: Be sure the end gap of the snap ring is not aligned with the upper side of the case.
      Fig 2: Installing Low Planetary Ring Gear Hole Snap Ring
      G02851685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL LOW PLANETARY GEAR BEARING, NO. 2 THRUST BEARING RACE AND INPUT SHAFT ASSEMBLY 
  3. INSTALL INPUT GEAR STOPPER BALL, LOW PLANETARY CARRIER THRUST WASHER AND INPUT GEAR STOPPER 
    1. Install the input gear stopper ball, low planetary carrier thrust washer and input gear stopper.
      Fig 3: Installing Input Gear Stopper Ball, Low Planetary Carrier Thrust Washer And Input Gear Stopper
      G02851686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a input gear stopper snap ring that allows 0.05-0.15 mm (0.0020-0.0059 in.) axial play.
      INPUT GEAR STOPPER SNAP RING SPECIFICATION

      Mark Thickness mm (in.)
      A 2.10-2.15(0.0827-0.0846)
      B 2.15-2.20(0.0846-0.0866)
      C 2.20-2.25 (0.0866-0.0886)
      D 2.25-2.30 (0.0886-0.0906)
      E 2.30-2.35 (0.0906-0.0925)
      F 2.35-2.40 (0.0925-0.0945)
      G 2.40-2.45 (0.0945-0.0965)
      H 2.45-2.50 (0.0965-0.0984)
      J 2.50-2.55 (0.0984-0.1004)
      K 2.55-2.60(0.1004-0.1024)
      L 2.60-2.65(0.1024-0.1043)
      M 2.65-2.70(0.1043-0.1063)
      N 2.70-2.75(0.1063-0.1083)
      P 2.75-2.80(0.1083-0.1102)
      Q 2.80-2.85(0.1102-0.1122)
      R 2.85-2.90(0.1122-0.1142)
      S 2.90-2.95(0.1142-0.1161)
      T 2.95-3.00 (0.1161-0.1181)
      U 3.00-3.05 (0.1181-0.1201)
    3. Using a snap ring expander, install a new input gear stopper snap ring.
      Fig 4: Installing Input Gear Stopper Snap Ring
      G02851687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL OUTPUT SHAFT NEEDLE ROLLER BEARING TO INPUT SHAFT 
  5. INSTALL LOW PLANETARY GEAR SPLINE PIECE 
    1. Install the low planetary gear spline piece.
    2. Using a screwdriver, install the low planetary gear snap ring.
      NOTE: Be sure the end gap of the snap ring is not aligned with cutout portion of the low planetary gear
  6. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY 
    1. Install the low planetary gear assembly with the input shaft assembly to the front case.
      Fig 5: Installing Low Planetary Gear Bearing Snap Ring
      G02851688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: If necessary, heat the front case to about 50-80 °C (122-176 °F).
    2. Using a snap ring expander, install the low planetary gear bearing snap ring.
      NOTE: Check that the low planetary gear assembly and input shaft assembly turn lightly.
  7. INSTALL OIL PUMP GEAR TO FRONT CASE 
  8. INSTALL OIL PUMP BODY ASSEMBLY 

    Install the oil pump body assembly with the 3 bolts.

    Torque: 7.5 N.m (80 kgf.cm, 69 in.lbf) 

  9. INSTALL MAGNET AND OIL SEPARATOR 
    1. Install the magnet to the front case.
    2. Install the oil separator with the 3 bolts.

      Torque: 7.5 N.m (80 kgf.cm, 69 in.lbf) 

  10. INSTALL ACTUATOR ASSEMBLY 
    1. Install a new O-ring, No. 1 and No. 2 4WD position switches with 2 new gaskets.

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

    2. Install the actuator assembly and clamp with the 3 bolts.

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

  11. INSTALL REAR OUTPUT SHAFT ASSEMBLY, NO. 1 GEAR SHIFT FORK, CENTER DIFF. LOCK FORK, DRIVEN SPROCKET ASSEMBLY AND FRONT DRIVE CHAIN 
    1. Install the No. 1 gear shift fork, center diff. lock fork, driven sprocket assembly and front drive chain to the rear output shaft assembly.
      NOTE: Make sure to install the forks in the correct direction.
    2. Install the rear output shaft assembly with the driven sprocket assembly to the rear case.
      Fig 6: Installing Rear Output Shaft Assembly With Driven Sprocket Assembly To Rear Case
      G02851689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not let the clutch sleeve and shifting key drop.
      NOTE: If necessary, heat the rear case to about 50-80 °C (122-176 °F).
    3. Using a snap ring expander, install the output shaft snap ring.
      NOTE: Check that the rear output shaft assembly and driven sprocket turn lightly.
    4. Using a screwdriver and hammer, drive in the 2 snap rings to the gear shift fork shaft of the actuator assembly.
      Fig 7: Driving In Snap Rings To Gear Shift Fork Shaft Of Actuator Assembly Using Screwdriver And Hammer
      G02851690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL GEAR SHIFT FORK SHAFT 
    1. Using a magnetic finger, install the 2 No. 2 shift interlock pins top the No. 1 gear shift fork and center diff. lock fork.
      Fig 8: Installing 2 No. 2 Shift Interlock Pins Top No. 1 Gear Shift Fork And Center Diff. Lock Fork
      G02851691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the slit portion of the gear shift fork shaft with it facing No. 2 shaft interlock pin and rotate the gear shift fork shaft, as shown in the illustration.
      Fig 9: Installing Slit Portion Of The Gear Shift Fork Shaft With It Facing No. 2 Shaft Interlock Pin
      G02851692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the shift shaft stopper with the bolt.

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

      Fig 10: Installing Shift Shaft Stopper With Bolt
      G02851693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 springs and balls to the No. 1 gear shift fork and center diff. lock fork.
      Fig 11: Installing 2 Springs And Balls To No. 1 Gear Shift Fork And Center Diff. Lock Fork
      G02851694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply sealant to the straight screw plug threads.

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

    6. Using a hexagon wrench, install the 2 straight screw plugs to the No. 1 gear shift fork and center diff. lock fork.

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

    7. Using a screwdriver and hammer, drive in the 3 snap rings to the gear shift fork shaft of the actuator assembly.
      Fig 12: Driving In Snap Rings To Gear Shift Fork Shaft Of Actuator Assembly
      G02851695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL HIGH AND LOW SHIFT FORK SHAFT, AND NO. 2 GEAR SHIFT FORK 
    1. Install the high and low shift fork shaft and No. 2 gear shift fork.
      Fig 13: Installing High And Low Shift Fork Shaft And No. 2 Gear Shift Fork
      G02851696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure to install the No. 2 gear shift fork in the correct direction.
    2. Using a pin punch and hammer, drive in the slotted spring pin to the No. 2 gear shift fork.
      Fig 14: Driving In Slotted Spring Pin To No. 2 Gear Shift Fork
      G02851697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL STRAIGHT SCREW PLUG, SPRING AND BALL 
    1. Install the ball and spring.
    2. Apply sealant to the straight screw plug threads.

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

    3. Using a hexagon wrench, install the 2 straight screw plugs.

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

      Fig 15: Installing Straight Screw Plugs Using Hexagon Wrench
      G02851698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a screwdriver and hammer, drive in the snap ring to the gear shift fork shaft.
      Fig 16: Driving In Snap Ring To Gear Shift Fork Shaft Using Screwdriver And Hammer
      G02851699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL REAR CASE 
    1. Apply FIPG to the rear case, as shown.

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

      Fig 17: Applying FIPG To Rear Case
      G02851700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Assemble the rear case and 2 clamps with the 12 bolts.

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

  16. INSTALL SHIFT HEAD NO. 2 
    1. Install the shift head No. 2.
    2. Using a pin punch and hammer, drive in the slotted spring pin to the shift head No. 2.
      Fig 18: Driving In Slotted Spring Pin To Shift Head No. 2 Using Pin Punch And Hammer
      G02851701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR AND OUTPUT SHAFT WASHER 
    1. Install the ball on the rear output shaft.
    2. Install the vehicle speed sensor drive gear and 2 output shaft washers.
  18. INSTALL EXTENSION HOUSING 
    1. Apply FIPG to the extension housing, as shown.

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

      Fig 19: Applying FIPG To Extension Housing
      G02851702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply sealant to the bolt threads.

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

    3. Install the extension housing with the 5 bolts.

      Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

  19. INSTALL FRONT COMPANION FLANGE 
    1. Install the front companion flange to the input shaft assembly.
    2. Using SST to hold the front companion flange, install a new front companion flange lock nut.

      SST 09330-00021

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

      Fig 20: Installing Front Companion Flange Lock Nut Using SST
      G02851703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Stake the front companion flange lock nut.
  20. INSTALL REAR COMPANION FLANGE 

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

  21. INSTALL TRANSFER UPPER COVER 

    Install a new oil deflector and the transfer upper cover with the 4 bolts.

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

  22. INSTALL FRONT BEARING RETAINER 
    1. Apply FIPG to the front bearing retainer, as shown.

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

      Fig 21: Applying FIPG To Front Bearing Retainer
      G02851704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 with the 5 bolts.

      Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 

  23. INSTALL L4 POSITION SWITCH, NEUTRAL POSITION SWITCH AND STRAIGHT SCREW PLUG WITH 3 NEW GASKETS 

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

  24. INSTALL VEHICLE SPEED SENSOR ASSEMBLY 
    1. Install the vehicle speed sensor driven gear to the vehicle speed sensor assembly with the clip.
    2. Install a new O-ring to the vehicle speed sensor assembly.
    3. Install the vehicle speed sensor assembly with the bolt.

      Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 

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