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Transfer Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE TRANSFER & TRANSAXLE SETTING STUD BOLT 
    1. Remove the 4 transfer & transaxle setting stud bolt.
  2. REMOVE NO. 2 TRANSFER CASE PLUG 
    1. Remove the transfer case No. 2 plug.
    2. Remove the gasket from the transfer case No. 2 plug.
      Fig 1: Removing No. 2 Transfer Case Plug
      G04464540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE NO. 1 TRANSFER CASE PLUG 
    1. Remove the transfer case No. 1 plug.
    2. Remove the gasket from the transfer case No. 1 plug.
      Fig 2: Removing No. 1 Transfer Case Plug
      G04464541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSFER DRAIN PLUG 
    1. Remove the transfer drain plug.
    2. Remove the gasket from the transfer drain plug.
  5. REMOVE TRANSFER CASE BREATHER PLUG 
    Fig 3: Removing Transfer Drain Plug
    G04464542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 1 TRANSFER CASE COVER 
    1. Remove the 8 bolts.
      Fig 4: Removing Bolts
      G04464543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the transfer case cover No. 1 from the case.
      NOTE: Place the brass bar on the rib part of the case.
    3. Remove the bolt and breather oil deflector.
      Fig 5: Removing No. 1 Transfer Case Cover
      G04464544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE TRANSFER DYNAMIC DAMPER 
    1. Remove the 3 bolts and transfer dynamic damper from the transfer extension housing.
  8. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 4 transfer case straight pins from the transfer case.
  9. FIX TRANSFER ASSEMBLY 
    1. Attach the transfer assembly to the overhaul attachment.
      Fig 6: Removing Transfer Dynamic Damper
      G04464545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR 
    1. Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.
      Fig 7: Removing Transfer Extension Housing Dust Deflector
      G04464546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing sub-assembly.

      SST 09308-00010 

      NOTE: Be careful of not damage the oil seal press in face of housing and the inner diameter of bush.
      Fig 8: Removing Transfer Extension Housing Type T Oil Seal
      G04464547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 4 bolts.
      Fig 9: Removing Transfer Extension Housing Sub-Assembly Bolts
      G04464548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the transfer extension housing sub-assembly from the case.
      Fig 10: Removing Transfer Extension Housing Sub-Assembly
      G04464549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT PRELOAD 
    1. Using SST and a torque wrench, measure the preload of the backlash between the driven pinion and ring gear.

      SST 09326-20011 

      Torque: Preload (at starting) 

      0.30 to 0.53 N*m (3.0 to 5.4 kgf*cm, 2.6 to 4.7 in.*lbf) 

    2. Using SST and a torque wrench, measure the total preload.
      Fig 11: Inspecting Preload
      G04464550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09326-20011 

      Torque: Preload (at starting) 

      0.49 to 0.86 N*m (5.0 to 8.8 kgf*cm, 4.3 to 7.6 in.*lbf) 

  14. INSPECT RING GEAR BACKLASH 
    1. Using a dial gauge, check the backlash of the ring gear.

      Backlash: 0.10 to 0.18 mm (0.0039 to 0.0071 in.) 

      If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

      NOTE: Check at least 3 positions on the circumference of the ring gear.
      Fig 12: Inspecting Ring Gear Backlash
      G04464551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION 
    1. Coat 3 or 4 teeth at 4 different positions on the ring gear with red lead.
      Fig 13: Inspecting Tooth Contact Between Ring Gear And Drive Pinion
      G04464552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Rotate the ring gear inspect the tooth pattern.
      Fig 14: Identifying Ring Patterns
      G04464553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE TRANSFER CASE OIL SEAL 
    1. Using SST, remove the transfer case oil seal from the transfer case.

      SST 09308-00010 

      NOTE: Do not damage the oil seal press in face of case.
      Fig 15: Removing Transfer Case Oil Seal
      G04464554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE TRANSFER CASE RH OIL SEAL 
    1. Using SST, remove the transfer case RH oil seal from the transfer case.

      SST 09308-00010 

      NOTE: Do not damage the oil seal press in face of case.
      Fig 16: Removing Transfer Case RH Oil Seal
      G04464555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE BEARING CAP 
    1. Remove the 2 bolts and the bearing cap.
      Fig 17: Removing Bearing Cap
      G04464556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER 
    1. Using SST, a screwdriver and a hammer, remove the transfer output shaft spacer No. 1.

      SST 09504-22011 

      NOTE: Protect with waste for not damaging the transfer case.
  20. REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER 
    Fig 18: Removing No. 1 Transfer Output Shaft Spacer
    G04464557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSFER RING GEAR MOUNTING CASE 
    1. Remove the transfer ring gear mounting case from the transfer case.
      Fig 19: Removing Transfer Ring Gear Mounting Case
      G04464558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE DRIVEN PINION 
    1. Using SST and a hammer, unstake the gear nut.

      SST 09930-00010 

      HINT:

      • Using SST with the flat side facing outward.
      • Do not machine the tip of SST with a grinder, etc.
        Fig 20: Unstaking Gear Nut
        G04464559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the gear nut.

      SST 09326-20011, 09556-16030 

      Fig 21: Removing Gear Nut
      G04464560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer.
      Fig 22: Removing Driven Pinion, Transfer Driven Pinion Rear Bearing Inner Race And Transfer Pinion Bearing Spacer
      G04464561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST and a press, remove the transfer driven pinion front bearing inner race.

      SST 09950-00020 

      Fig 23: Removing Transfer Driven Pinion Front Bearing Inner Race
      G04464562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, tap the driven pinion front bearing outer race to remove from the case.
      NOTE: Place the brass bar at the 2 positions of the cutouts on the case.
  24. REMOVE TRANSFER OUTPUT WASHER 
  25. REMOVE RING GEAR MOUNTING CASE BEARING 
    1. Remove the ring gear mounting case bearing RH outer race from the transfer ring gear mounting case.
      Fig 24: Removing Transfer Driven Pinion Front Bearing
      G04464563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the ring gear mounting case bearing RH inner race from the transfer ring gear mounting case.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00440) 

      NOTE: Using SST (09953-04020) with its screw and tip applied to grease.
      Fig 25: Removing Ring Gear Mounting Case Bearing RH
      G04464564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the ring gear mounting RH inner race from the transfer ring gear mounting case.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00400) 

      NOTE: Using SST (09953-04020) with its screw and tip applied to grease.
      Fig 26: Removing Ring Gear Mounting RH Inner Race From Transfer Ring Gear Mounting Case
      G04464565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a brass bar and a hammer, tap the 2 positions of the ring gear mounting case bearing LH outer race to remove from the transfer case.
      NOTE: Place the brass bar at the 2 positions of the cutouts on the case.
    5. Remove the ring gear mounting case plate washer.
      Fig 27: Removing Ring Gear Mounting Case Bearing LH
      G04464566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSPECT RUNOUT OF RING GEAR 
    1. Place the transfer ring gear mounting case on the V-block.
    2. Using a dial gauge, check the runout of the ring gear.

      Maximum runout: 0.06 mm (0.0024 in.) 

      Fig 28: Inspecting Runout Of Ring Gear
      G04464567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE RING GEAR 
    1. Make matchmarks on the transfer ring gear mounting case and the ring gear.
    2. Remove the 10 bolts.
      Fig 29: Making Matchmarks On Transfer Ring Gear Mounting Case And Ring Gear
      G04464568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, tap on the ring gear to separate it from the transfer ring gear mounting case.
      NOTE: Do not damage the tooth face of the ring gear.
      Fig 30: Removing Ring Gear
      G04464569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSPECT TRANSFER RING GEAR MOUNTING CASE 
    1. Place the transfer ring gear mounting case on the V-block.
    2. Using a dial gauge, check the runout of the ring gear.

      Maximum runout: 0.14 mm (0.0055 in.) 

      Fig 31: Inspecting Transfer Ring Gear Mounting Case
      G04464570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE TRANSFER DRIVEN PINION REAR BEARING 
    1. Using a brass bar and a hammer, tap the 2 positions on the driven pinion rear bearing outer race before removing from the transfer case.
      NOTE: Place the brass bar at the 2 positions of the cutouts on the case.
      Fig 32: Removing Transfer Driven Pinion Rear Bearing
      G04464571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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