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Transfer Case Reassembly

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  1. Install transfer driven pinion rear bearing using the following steps:
    1. Using adapter and a press, press the driven pinion bearing rear outer race into the case.
      NOTE: Keep the transfer case horizontally using tip of wood, etc.
    2. Apply gear oil to the driven pinion bearing rear outer race.
  2. Install original transfer output washer to the case. See Figure. Apply gear oil to the washer.
  3. Install transfer driven pinion front bearing using following steps:
    1. Apply gear oil to the inner surface of the transfer case.
    2. Using appropriate bearing race installer, install the driven pinion bearing front outer race to the case with a bolt and a nut. See Fig 1.
    3. Using appropriate adapter and a press, press the driven pinion bearing front inner race into the driven pinion.
  4. Install driven pinion using following steps:
    1. Install the driven pinion to the case.
      NOTE: Install the pinion bearing spacer with the larger inner diameter coming to the front side.
    2. Install a new pinion bearing spacer and driven pinion bearing rear inner race to the driven pinion. See Figure.
      NOTE: Use a torque wrench with a fulcrum length of 15.03" (380 mm). Torque value is most accurate with the torque wrench parallel to gear nut wrench.
    3. Secure driven pinion with Drive Pinion Holding Tool (09556-16030). See Figure. Install a new gear nut. Tighten nut to 191-262 ft. lbs. (260-355 N.m).
    NOTE: Do not stake the nut until the final adjustment of the preload, tooth contact and backlash is completed.
  5. Adjust driven pinion preload. Using INCH lb. torque wrench, measure the driven pinion preload (at starting). See Figure. Starting preload should be 4.6-8.6 INCH lbs. (.52-.97 N.m) for new bearing or 2.7-4.6 INCH lbs. (.30-.52 N.m) for used bearing.
    • If the preload is not sufficient, adjust the driven pinion by tightening the lock nut by 5-10 degrees and measuring the preload until the preload is within the standard value. If the preload is more then the standard value, replace the spacer with a new one.
    • If the tightening torque for a driven pinion nut is more than the standard value, and the preload is not sufficient, loosen the lock nut, apply gear oil on the thread and bearing surface and adjust it as described above. When the tightening torque is less than the standard value, replace the spacer with a new one.
  6. Install ring gear using following steps:
    1. Clean the contact surface of the ring gear and transfer ring gear mounting case.
    2. Heat the ring gear in water and boil for 10 minutes.
    3. Carefully remove the ring gear from the water.
    4. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the transfer ring gear mounting case. Ensure matchmarks meet.
      NOTE: Tighten ring gear bolts in diagonal pattern.
    5. Install the 12 bolts. Tighten to specification after ring gear has cooled down. See TORQUE SPECIFICATIONS .
  7. Install ring gear mounting case bearings using the following steps:
    1. Using appropriate adapter and a press, press the ring gear mounting case RH bearing inner race onto the ring gear mounting case. See Figure.
    2. Install the ring gear mounting case RH bearing outer race to the ring gear mounting case.
    3. Apply gear oil to the ring gear mounting case RH bearing.
    4. Using appropriate adapter and a press, press the ring gear mounting case LH inner race onto the ring gear mounting case.
    5. Install the original washer to the case.
    6. Using appropriate adapter and a press, press the ring gear mounting case LH bearing outer race into the case.
    7. Apply gear oil to the ring gear mounting case bearing.
  8. Apply gear oil to the ring gear mounting case. Install the ring gear mounting case to the transfer case.
  9. To install a new transfer output shaft spacer No. 1, align the cutouts on it with the hole of the case. See Fig 2.
  10. Install original transfer ring gear mounting No. 2 case washer as follows: using a brass bar and a hammer, install a new No. 2 case washer. See Fig 3.
  11. Install the bearing cap with the 2 bolts. Tighten bolts to 47 ft. lbs. (63 N.m).
    NOTE: Check backlash at least 3 positions on the circumference of the ring gear.
  12. Inspect backlash using following steps:
    1. Place a dial indicator on the teeth surface on the ring gear vertically, check with fixing the driven pinion and moving the ring gear. See Figure. Backlash should be .004-.006" (.10-.15 mm).
    2. If the backlash is not in the range of specified value, select a different ring gear mounting case LH bearing side washer and install it to meet the specified value. See Fig 4. Washers are marked in numeric order and are available in thicknesses from .081" (2.05 mm), marked with the number "50", to .121" (3.07 mm), marked with the number "84", in increments of .0012" (.03 mm).
    NOTE: When the washer thickness is changed, readjust the backlash.
  13. Inspect tooth contact between ring gear and driven pinion using the following steps:
    1. Coat 3 or 4 teeth at the 4 different positions on the ring gear with red lead. See Figure.
    2. Rotate the ring gear and inspect the tooth pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. If the teeth are not contacting properly, select the proper washer. See Fig 4. Washers are marked in alpha order and are available in thicknesses from .083" (2.10 mm), marked with the letters "AA", to .100" (2.54 mm), marked with the letters "QC", in increments of .0008" (.02 mm).
    NOTE: Use a torque wrench with a fulcrum length of 6.3" (160 mm ). Turn the driven pinion counterclockwise and clockwise several times.
  14. Adjust total preload using following steps:
    1. Using INCH lb. torque wrench, measure the driven pinion total preload. See Figure. Total preload should be 7.3-12.6 INCH lbs. (.82-1.42 N.m) for new bearing or 4.4-7.5 INCH lbs. (.49-.85 N.m) for used bearing.
    2. If the preload is not within specification, select proper washer. See Fig 4. Washers are marked in alpha/numeric order and are available in thicknesses from .097" (2.47 mm), marked with "A0", to .150" (3.82 mm), marked with "E5", in increments of .0012" (.03 mm).
    3. Using a chisel and a hammer, stake the gear nut.
    NOTE: Do not install the oil seal at an angle.
  15. Install transfer case RH oil seal using following steps:
    1. Using appropriate driver and a hammer, drive a new oil seal into the case until it reaches the depth position of 1.328-1.350" (33.7-34.3 mm) below edge of case.
    2. Apply a small amount of multi-purpose grease to the lip of the oil seal.
  16. Install transfer case oil seal in the following steps:
    1. Using appropriate driver and a hammer, drive a new oil seal into the case until it reaches the depth position of .328-.406" (9.7-10.3 mm) below edge of case.
    2. Apply a small amount of multi-purpose grease to the lip of the oil seal.
  17. Install transfer extension housing oil seal using the following steps:
    1. Using appropriate driver and a hammer, drive a new oil seal into the case until it reaches the depth position of .043-.075" (1.1-1.9 mm) below edge of extension housing.
    2. Apply a small amount of multi-purpose grease to the lip of the oil seal.
  18. Using appropriate adapter and a press, install the dust deflector to the extension housing.
  19. Install transfer extension housing in the following steps:
    1. Remove any sealant material and be careful not to drop oil on the contacting surfaces of the extension housing and the transfer case.
    2. Degrease the surface with white gasoline.
    3. Apply appropriate sealant to the extension housing.
      NOTE: Assemble transfer extension housing within one minute after sealant application.
    4. Install the extension housing with the 4 bolts to the case. See TORQUE SPECIFICATIONS .
  20. Remove the transfer assembly from the overhaul fixture.
  21. Using a plastic hammer, drive the 4 straight pins into transfer case.
  22. Install the transfer dynamic damper with the 3 bolts to the extension housing.
  23. Install transfer case breather plug.
  24. Install transfer case cover No. 1 using the following steps:
    1. Install the breather oil deflector with the bolt. Tighten bolt to 58 INCH lbs. (6.5 N.m).
    2. Remove any sealant material and be careful not to drop oil on the contacting surfaces of the transfer case cover No. 1 and the transfer case.
    3. Degrease the surface with white gasoline.
    4. Apply appropriate sealant to the transfer case cover No. 1.
      NOTE: Assemble transfer case cover No. 1 within 10 minutes after application of sealant. Wait at least an hour before filling with transfer assembly with oil.
    5. Install the transfer case cover No. 1 with the 8 bolts.
  25. Install a new gasket to the transfer drain plug. Install the transfer drain plug to the transfer assembly. See TORQUE SPECIFICATIONS .
  26. Install a new gasket to the transfer case No. 2 plug. Temporary tighten the transfer case No. 2 plug to the transfer assembly. See Figure.
  27. Install a new gasket to the transfer case No. 1 plug. Install the transfer case No. 1 plug to the transfer assembly.
  28. Install transfer and transaxle setting stud bolt as follows: install the 4 stud bolts to the correct position. See Fig 5.
    NOTE: Install the transfer assembly to the transaxle assembly horizontally. Do not touch the oil seal part of the transfer assembly when installation.
  29. Install transfer assembly as follows: install the transfer assembly with the 6 nuts to the transaxle assembly. See TORQUE SPECIFICATIONS .
  30. Install the stiffener plate RH with the 4 bolts. See Figure.
  31. Install the stiffener plate center with the 5 bolts.
  32. Install the engine mounting bracket with the 3 bolts.
  33. Install RH front drive shaft assembly. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
  34. Install starter assembly. See appropriate STARTERS article in ELECTRICAL.
  35. Install exhaust manifold. See appropriate article in ENGINES.
  36. Install exhaust manifold heat insulator No. 1. See appropriate article in ENGINES.
  37. Install oxygen sensor. See appropriate article in ENGINES.
  38. Install manifold stay. See appropriate article in ENGINES.
  39. Install front suspension crossmember w/center member. See appropriate article in ENGINES.
  40. Install rack and pinion power steering gear assembly. See appropriate POWER RACK & PINION article in STEERING.
  41. Install vane (power steering) pump assembly. See appropriate POWER RACK & PINION article in STEERING.
  42. Install engine assembly with transaxle. See appropriate article in ENGINES.
  43. Add transfer oil. See appropriate SERVICING article. Tighten transfer case plug No. 2 to specification. See TORQUE SPECIFICATIONS .
  44. Check automatic transaxle fluid. Add as needed. See appropriate SERVICING article.
  45. Check and add engine coolant as needed. See appropriate COOLING SYSTEM (MECHANICAL) article in ENGINES.
  46. Check for engine oil leaks. Repair as needed.
  47. Check engine coolant leaks. Repair as needed.
  48. Check fuel leaks. Repair as needed.
  49. Check exhaust gas leaks. Repair as needed.
  50. Check idle speed and ignition timing. See appropriate ON-VEHICLE ADJUSTMENTS article in ENGINE PERFORMANCE.
  51. Inspect exhaust emissions.
  52. Inspect and adjust front wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in SUSPENSION.
  53. Check ABS signal. See appropriate ANTI-LOCK/TRACTION CONTROL article in BRAKES.
Fig 1: Installing Driven Pinion Outer Bearing Race
G00079194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Aligning No. 1 Spacer Cutouts
G00079190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Installing Ring Gear Mounting No. 2 Case Washer
G00079191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 4: Identifying Transfer Assembly Adjustment Washers
G00079193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 5: Locating Transfer Assembly Stud Bolts
G00079192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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