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Home >> Toyota >> 2003 >> Matrix Base, FWD, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Transfer Case Overhaul) >> Overhaul >> Transfer Assembly Disassembly
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Transfer Assembly Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. Remove engine assembly with transaxle. See appropriate article in ENGINES.
  2. Separate vane (power steering) pump assembly. See appropriate POWER RACK & PINION article in STEERING.
  3. Remove rack and pinion power steering gear assembly. See appropriate POWER RACK & PINION article in STEERING.
  4. Remove front suspension crossmember w/center member. See appropriate article in ENGINES.
  5. Remove manifold stay. See appropriate article in ENGINES.
  6. Remove oxygen sensor. See appropriate article in ENGINES.
  7. Remove exhaust manifold heat insulator No. 1. See appropriate article in ENGINES.
  8. Remove exhaust manifold. See appropriate article in ENGINES.
  9. Remove starter assembly. See appropriate STARTER article in ELECTRICAL.
  10. Remove RH front driveshaft assembly. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
  11. Remove RR engine mounting bracket. See Fig 1.
  12. Remove center transfer stiffener plate.
  13. Remove RH transfer stiffener plate.
  14. Remove transfer assembly using following steps:
    1. Remove the 6 nuts.
      NOTE: Remove the transfer assembly horizontally from the transaxle assembly. When removing, do not touch both sides of transfer assembly oil seal.
    2. Using a plastic hammer, remove the transfer assembly from the transaxle assembly.
  15. Remove 4 transfer and transaxle setting stud bolts. See Fig 2.
  16. Remove transfer case No. 1 plug. Remove the gasket from the transfer case No. 1 plug.
  17. Remove transfer case No. 2 plug. Remove the gasket from the transfer case No. 2 plug.
  18. Remove transfer drain plug. Remove the gasket from the transfer drain plug.
  19. Remove transfer case breather plug on transfer case cover No. 1.
  20. Remove transfer case cover No. 1 using the following steps:
    1. Remove the 8 bolts.
      NOTE: Place the brass bar on the rib part of the case cover.
    2. Using a brass bar and a hammer, remove the transfer case cover No. 1 from the case.
    3. Remove the bolt and breather oil deflector. See Fig 2.
  21. Remove transfer dynamic damper. Remove the 3 bolts and transfer dynamic damper from the extension housing.
  22. Remove the 4 transfer case straight pins from the transfer case.
  23. Attach the transfer assembly to an appropriate overhaul fixture.
  24. Remove transfer extension housing dust deflector. Using a plastic hammer, remove the transfer extension housing dust deflector from the extension housing.
    NOTE: Be careful of not damaging the oil seal portion of extension housing and the inner diameter of bushing.
  25. Using appropriate oil seal puller, remove the oil seal from the extension housing.
  26. Remove transfer extension housing using following steps:
    1. Remove the 4 bolts.
    2. Using a plastic hammer, remove the extension housing from the case.
    NOTE: Ensure torque wrench has a fulcrum length of 6.3" (160 mm). Torque value is most accurate when torque wrench is parallel with gear nut wrench.
  27. Inspect preload using following steps:
    1. Using Output Shaft Bearing Lock Nut Wrench (09326-20011) and a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. See Fig 3. Preload (at starting) should be 2.8-5.0 INCH lbs. (.32-.57 N.m).
    2. Measure the total preload. Preload (at starting) should be 4.7-8.3 INCH lbs. (.53-.94 N.m).
  28. Inspect backlash as follows: using a dial indicator, check the backlash of the ring gear. See Fig 4. Check at least 3 positions on the circumference of the ring gear. Backlash should be .004-.006" (.10-.15 mm). If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
  29. Inspect tooth contact between ring gear and driven pinion using following steps:
    1. Coat 3 or 4 teeth at 4 different positions on the ring gear with red lead. See Fig 5.
    2. Rotate the ring gear and inspect the tooth pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION.
    NOTE: Be careful of not damaging the oil seal bore.
  30. Remove transfer case oil seal. See Fig 2. Using appropriate puller, remove the oil seal from the case.
  31. Remove transfer case RH oil seal. Using appropriate puller, remove the oil seal from the case.
  32. Remove the bearing cap. Remove the 2 bolts and the bearing cap.
    NOTE: Use care not to damage transfer case.
  33. Remove transfer output shaft spacer as follows: using appropriate hook tool, a screwdriver and a hammer, remove the transfer output shaft spacer No. 1. See Fig 6.
  34. Remove transfer ring gear mounting case washer No. 2. See Fig 2.
  35. Remove the transfer ring gear mounting case from the transfer assembly.
  36. Remove driven pinion using the following steps:
    1. Using appropriate chisel and a hammer, unstake the gear nut. See Fig 7.
    2. Using Drive Pinion Holding Tool (09556-16030), remove the gear nut. See Fig 8.
    3. Using a press, remove the driven pinion, transfer driven pinion bearing rear inner race and transfer pinion bearing spacer.
  37. Remove transfer driven pinion front bearing using following steps:
    1. Using appropriate bearing separator and a press, remove the transfer driven pinion front bearing inner race.
      NOTE: Place the brass bar at the 2 positions of the cutouts on the case.
    2. Using a brass bar and a hammer, tap the driven pinion front bearing outer race to remove from the case.
  38. Remove transfer output washer. See Fig 2.
  39. Remove ring gear mounting case bearing using the following steps:
    1. Remove the ring gear mounting case RH bearing outer race from the ring gear mounting case.
      NOTE: Apply grease to puller screw and tip.
    2. Using appropriate bearing separator and puller, remove the ring gear mounting case RH bearing inner race from the ring gear mounting case assembly.
      NOTE: Apply grease to puller screw and tip.
    3. Using appropriate bearing separator and puller, remove the ring gear mounting case LH bearing inner race from the ring gear mounting case assembly.
      NOTE: Place the brass bar at the 2 positions of the cutouts on the case.
    4. Using a brass bar and a hammer, tap the 2 positions of the ring gear mounting case LH bearing outer race to remove from the case.
    5. Remove the case washer. See Fig 2.
  40. Inspect runout of ring gear using following steps:
    1. Place the ring gear mounting case assembly on the V-blocks.
    2. Using a dial indicator, check the runout of the ring gear. See Fig 9. Maximum runout is .002" (.06 mm).
  41. Remove ring gear using following steps:
    1. Make matchmarks on the ring gear mounting case and the ring gear.
    2. Remove the 10 bolts.
      NOTE: Do not damage the tooth face of the ring gear.
    3. Using a plastic hammer, tap on the ring gear to separate it from the ring gear mounting case.
  42. Inspect runout of transfer ring gear mounting case using following steps:
    1. Place the ring gear mounting case assembly on the V-block.
    2. Using a dial indicator, check the runout of the ring gear mounting case. Maximum runout is .006" (.15 mm).
    NOTE: Place the brass bar at the 2 positions of the cutouts on the case.
  43. Using a brass bar and a hammer, tap the 2 positions on the driven pinion bearing rear outer race to remove from the case.
Fig 1: Removing/Installing Transfer Assembly
G00079182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Exploded View Of Transfer Assembly
G00079183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Measuring Driven Pinion Preload
G00079184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 4: Measuring Transfer Gear Backlash
G00079185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 5: Applying Red Lead To Ring Gear
G00079186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 6: Removing Output Shaft Spacer No. 1
G00079187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 7: Unstaking Driven Gear Nut
G00079188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 8: Removing/Installing Driven Gear Lock Nut
G00079189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 9: Measuring Ring Gear Runout
G00079161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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