Transfer Assembly: Disassembly

REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT
1. Remove the stud bolt.
  
  Fig 1: Identifying Transaxle Setting Stud Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE STRAIGHT PIN
1. Remove the 2 straight pins.
REMOVE TRANSFER CASE NO. 1 PLUG
1. Remove the No. 1 plug.
2. Remove the gasket from the No. 1 plug.
  
  Fig 2: Locating Straight Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE NO. 2 PLUG
1. Remove the No. 2 plug.
2. Remove the gasket from the No. 2 plug.
  
  Fig 3: Identifying Transfer Case No. 2 Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRAIN PLUG
1. Remove the drain plug.
2. Remove the gasket from the drain plug.
  
  Fig 4: Identifying Transfer Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE OIL SEAL LH
1. Using SST, tap out the oil seal from the case.
  SST 09308-00010
  
  NOTE: Do not damage the oil seal lip.
  
  Fig 5: Removing Transfer Case Oil Seal LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE OIL SEAL RH
1. Using SST, tap out the oil seal from the case.
  SST 09308-00010
  
  NOTE: Do not damage the oil seal lip.
  
  Fig 6: Removing Transfer Case Oil Seal RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT RING GEAR BACKLASH
1. Using a dial indicator, measure the backlash of the ring gear at 3 points.
  Standard backlash:
  
  0.10 to 0.20 mm (0.0039 to 0.0079 in.)
  
  If the backlash is not within the specified range, adjust the backlash or repair as necessary.
  
  Fig 7: Measuring Backlash Of Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TRANSFER CASE COVER
1. Remove the 8 bolts.
  
  Fig 8: Locating No. 1 Transfer Case Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap out the cover from the case.
  
  Fig 9: Tapping Out Cover From Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER RING GEAR
1. Remove the ring gear from the transfer case.
REMOVE TRANSFER CASE STRAIGHT PIN
1. Remove the 2 straight pins from the transfer case.
  
  Fig 10: Identifying Ring Gear And Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT SHAFT
1. Remove the 5 bolts and output shaft.
  
  Fig 11: Locating Transfer Output Shaft Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, unstake the lock nut.
  SST 09930-00010
3. Remove the lock nut.
  
  Fig 12: Unstaking Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT REAR SHAFT SUB-ASSEMBLY
1. Using SST and a press, press out the shaft from the driven pinion.
  SST 09950-00020, 09950-60010 (09951 -00220), 09950-70010 (09951-07100)
  
  Fig 13: Pressing Out Shaft From Driven Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVEN PINION FRONT BEARING
1. Using SST and a press, press out the driven pinion from the bearing.
  SST 09950-00020, 09950-60010 (09951-00220), 09950-70010 (09951-07100)
  
  Fig 14: Pressing Out Driven Pinion From Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the bearing.
  
  Fig 15: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT SHAFT WASHER
1. Remove the washer from the transfer pinion gear.
  
  Fig 16: Identifying Transfer Pinion Gear Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RING GEAR MOUNTING CASE BEARING (for LH side)
1. Using SST, remove the bearing from the mounting case.
  SST 09950-40011 (09951 -04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00540)
  
  Fig 17: Removing Bearing From Mounting Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the bearing.
  SST 09310-35010
REMOVE RING GEAR MOUNTING CASE WASHER

Fig 18: Tapping Out Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RING GEAR MOUNTING CASE BEARING (for RH side)
1. Using SST, remove the bearing from the mounting case.
  SST 09950-40011 (09951-04010,09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00540)
  
  Fig 19: Removing Bearing From Mounting Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the bearing (race) from the cover.
  SST 09636-20010
REMOVE TRANSFER RING GEAR MOUNTING CASE NO. 2 WASHER
REMOVE SHAFT SNAP RING
1. Using a snap ring expander, remove the snap ring.
  
  Fig 20: Removing Snap Ring Using Snap Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER RING GEAR MOUNTING CASE
1. Using SST and a press, press out the ring gear from the mounting case.
  SST 09950-60010 (09951-00400)
  
  Fig 21: Pressing Out Ring Gear From Mounting Case Using SST And Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BREATHER OIL DEFLECTOR
1. Remove the 2 bolts and oil deflector.
  
  Fig 22: Identifying Breather Oil Deflector With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE BREATHER PLUG
1. Remove the breather plug from the transfer case.
  
  Fig 23: Locating Transfer Case Breather Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002