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Transfer Unit: Disassembly

  1. REMOVE TRANSFER COVER GASKET 
    1. Remove the transfer gasket from the transfer assembly.
      Fig 1: Locating Transfer Cover Gasket To Transfer Case
      G05241019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE TRANSFER CASE BREATHER PLUG 
    1. Using a screwdriver and a hammer, remove the transfer case breather plug from the No. 1 transfer case cover.
      NOTE: Be careful not to damage the contact surface of No. 1 case cover.
      Fig 2: Locating Transfer Case Breather Plug
      G05241020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE NO. 1 TRANSFER CASE COVER 
    1. Remove the 8 bolts.
      Fig 3: Locating Transfer Case Cover No 1 With Bolt
      G05241021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the No. 1 transfer case cover from the transfer case.
      NOTE: Be careful not to damage the contact surfaces of the case and cover.
      Fig 4: Removing Transfer Case Cover From Transfer Case
      G05241022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE BREATHER OIL DEFLECTOR 
    1. Remove the bolt and breather oil deflector from the No. 1 transfer case cover.
      Fig 5: Locating Breather Oil Deflector
      G05241023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSFER DYNAMIC DAMPER 
    1. Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing sub-assembly.
    Fig 6: Locating Transfer Dynamic Damper And Bolts
    G05241024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 4 transfer case straight pins from the transfer case.
  7. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. Remove the 4 transfer and transaxle setting stud bolts.
  8. FIX TRANSFER ASSEMBLY 
    1. Fix the transfer assembly to the overhaul attachment.
  9. 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
      G05241025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST(s), remove the transfer extension housing type T oil seal from the transfer extension housing.

      SST 09308-00010 

      NOTE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.
      Fig 8: Removing Transfer Extension Housing Type T Oil Seal Using SST
      G05241026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 4 bolts.
      Fig 9: Locating Transfer Extension Housing Sub-Assembly With Bolts
      G05241027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the transfer extension housing sub- assembly from the transfer case.
      Fig 10: Removing Transfer Extension Housing Sub-Assembly
      G05241028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT PRELOAD 
    1. Using SST(s) and a torque wrench, check the initial torque with the backlash range.

      SST 09326-20011 

      Torque: 0.9 to 1.4 N*m (9 to 14 kgf*cm, 8.0 to 12.4 in.*lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)

      2. Fig 11: Checking Initial Torque With Backlash Range
      G05241029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST(s) and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.

      SST 09326-20011 

      Torque: Preload 

      + 0.15 to 0.30 N*m (+ 1.6 to 3.1 kgf*cm, + 1.3 to 2.7 in.*lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)

  13. REMOVE CTR DIFFERENTIAL LOCK SLEEVE 
    1. Using snap ring pliers, remove the shaft snap ring.
      Fig 12: Removing Shaft Snap Ring
      G05241030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST(s), remove the CTR differential lock sleeve.

      SST 09308-00010 

      Fig 13: Removing CTR Differential Lock Sleeve
      G05241031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE O-RING 
    1. Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.
      NOTE: Be careful not to damage the lock sleeve's groove for the O-ring.
      Fig 14: Removing O-Ring
      G05241032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSFER CASE OIL SEAL 
    1. Using SST(s), remove the transfer case oil seal from the case.

      SST 09308-00010 

      NOTE: Be careful not to damage the oil-seal-fitted surface of the case.
      Fig 15: Removing Transfer Case Oil Seal
      G05241033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST(s), remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.

      SST 09308-00010 

      NOTE: Be careful not to damage the oil-seal-fitted v surface of the retainer.
      Fig 16: Removing Transfer RH Bearing Retainer Oil Seal
      G05241034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY 
    1. Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.
      Fig 17: Locating Transfer RH Bearing Retainer Sub-Assembly With Bolts
      G05241035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, make a clearance between the transfer RH bearing retainer sub-assembly and the transfer case.

      SST 09950-00020 

    3. Remove the SST.
      Fig 18: Identifying Transfer RH Bearing Retainer Sub-Assembly And Transfer Case With SST
      G05241036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, remove the transfer RH bearing retainer sub-assembly from the transfer case.

      SST 09520-10021 

      Fig 19: Removing Transfer RH Bearing Retainer Sub-Assembly From Transfer Case
      G05241037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE O-RING 
    1. Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assembly.
      NOTE: Be careful not to damage the retainer's grooves for the O-rings.
      Fig 20: Removing O-Rings From Transfer RH Bearing Retainer Sub-Assembly
      G05241038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Fix the transfer RH bearing retainer sub-assembly in a vise.
    2. Using SST(s), remove the center differential case tapered roller bearing RH outer race, transfer ring gear mounting case washer No. 2 and right bearing retainer oil seal No. 2 from the transfer RH bearing retainer sub-assembly.

      SST 09308-00010 

      NOTE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer sub-assembly.
      Fig 21: Removing Center Differential Case Tapered Roller Bearing
      G05241039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE SIDE GEAR SHAFT HOLDER BEARING 
    1. Using snap ring pliers, remove the side gear shaft holder hole snap ring.
    2. Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assembly.
      Fig 22: Removing Side Gear Shaft Holder Bearing
      G05241040Courtesy 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 23: Removing Transfer Ring Gear Mounting Case
      G05241041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
      NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
      Fig 24: Removing Differential Case Tapered Roller Bearing Using SST(s)
      G05241042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
      NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
      Fig 25: Removing Inner Race Of Center Differential Case Tapered Roller Bearing Using SST(s)
      G05241043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
      NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
      Fig 26: Removing Inner Race Of Center Differential Case Tapered Roller Bearing With SST(s)
      G05241044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
      NOTE: Apply grease to the screw thread and tip of the SST(s) before use.
      Fig 27: Removing Center Differential Case Tapered Roller Bearing Using SST(s)
      G05241045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE RING GEAR 
    1. Put matchmarks on the transfer ring gear mounting case and the ring gear.
    2. Remove the 12 bolts.
      Fig 28: Identifying Matchmarks On Transfer Ring Gear Mounting Case And Ring Gear
      G05139129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, remove the ring gear by tapping around its periphery.
      NOTE: Do not damage the teeth of the ring gear.
      Fig 29: Removing Ring Gear
      G05241047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSFER GEAR NUT 
    1. Using SST(s) and a hammer, unstake the transfer gear nut.

      SST 09930-00010 

      Fig 30: Unstaking Transfer Gear Nut Using SST(s)
      G05241048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST(s), remove the transfer gear nut.
      Fig 31: Removing Transfer Gear Nut Using SST(s)
      G05241049Courtesy 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.
      NOTE:
      • Put shop cloths around to help prevent the driven pinion from bearing dropped.
      • Place something like wood blocks under the case to keep it level.
        Fig 32: Identifying Driven Pinion, Transfer Driven Pinion Rear Bearing Inner Race And Transfer Pinion Bearing Spacer
        G05241050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST(s) and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.

      SST 09950-00020 

      Fig 33: Identifying Transfer Driven Pinion Front Bearing
      G05241051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 positions to remove it from the transfer case.
    Fig 34: Removing Center Differential Case Tapered Roller Bearing
    G05241052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE TRANSFER OUTPUT WASHER 
    1. Remove the ring gear mounting case plate washer from the transfer case.
  28. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.
    Fig 35: Removing Center Differential Case Tapered Roller Bearing
    G05241053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE RING GEAR MOUNTING CASE PLATE WASHER 
    1. Remove the transfer output washer from the transfer case.
  30. REMOVE TRANSFER DRIVEN PINION REAR BEARING 
    1. Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.
      Fig 36: Removing Transfer Driven Pinion Rear Bearing
      G05241054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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