Transfer Assembly: Reassembly: Reassembly

INSTALL TRANSFER DRIVEN PINION REAR BEARING
1. Using SST and a press, press the driven pinion rear bearing (outer race) into the case.
  
  Fig 1: Installing Transfer Driven Pinion Rear Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00620
  - SST: 09950-70010
    - 09951-07150
  NOTE:
  Use wooden blocks or similar objects under the case to keep it level.
2. Apply gear oil to the driven pinion rear bearing (outer race).
INSTALL TRANSFER OUTPUT SHAFT WASHER
1. Install the transfer output shaft washer to the transfer case.
  HINT:
  
  Install the same washer as the one removed.
2. Apply gear oil to the transfer output shaft washer.
INSTALL TRANSFER DRIVEN PINION FRONT BEARING
1. Apply gear oil to the inner surface of the transfer case.
  
  Fig 2: Installing Transfer Driven Pinion Front Bearing (Outer Race) To Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install the transfer driven pinion front bearing (outer race) to the transfer case.
  - SST: 09950-60010
    - 09951-00610
    - 09951-00620
    - 09951-00650
  - SST: 09950-60020
    - 09951-00680
3. Using SST and a press, press the driven pinion front bearing (inner race) into the driven pinion.
  
  Fig 3: Pressing Driven Pinion Front Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09506-30012
INSTALL DRIVEN PINION
1. Install the driven pinion to the transfer case.
  
  Fig 4: Installing Driven Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new transfer pinion bearing spacer and driven pinion rear bearing (inner race) to the driven pinion.
  
  Fig 5: Identifying Transfer Pinion Bearing Spacer And Driven Pinion Rear Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Install the pinion bearing spacer with the larger inner diameter facing forward as shown in the illustration.
3. Using SST, install a new gear nut.
  - SST: 09326-20011
  - SST: 09556-16030
  without SST
  
  Torque: 270 to 420 N*m (2751 to 4280 kgf*cm, 198 to 308 ft.*lbf)
  
  with SST
  
  Torque: 254 to 396 N*m (2588 to 4035 kgf*cm, 186 to 291 ft.*lbf)
  
  Fig 6: Installing Gear Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Using a torque wrench with a fulcrum length of 840 mm (33.07 ft.).
  
  NOTE:
  Do not stake the nut until the final preload, tooth contact and backlash adjustments are completed.

ADJUST DRIVEN PINION PRELOAD

Using SST and a torque wrench, measure the driven pinion preload.

Fig 7: Measuring Total Preload

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09326-20011

Preload (at Starting)

Item	Preload
New bearing (without SST)	0.68 to 1.13 Nm (7 to 11 kgfcm, 6 to 10 in.*lbf)
New bearing (with SST)	0.49 to 0.81 Nm (5 to 8 kgfcm, 5 to 7 in.*lbf)
Reused bearing (without SST)	0.56 to 0.94 Nm (6 to 9 kgfcm, 5 to 8 in.*lbf)
Reused bearing (with SST)	0.40 to 0.67 Nm (4 to 6 kgfcm, 4 to 5 in.*lbf)

HINT:

Use a torque wrench with a fulcrum length of 130 mm (5.12 in.).
If the preload is more than the specification, replace the pinion bearing spacer with a new one.
If the preload is not sufficient, adjust the driven pinion by tightening the lock nut 5° to 10° and measuring the preload until the preload is within the specification.
Even if the tightening torque of the gear nut exceeds the specified torque, if the preload is insufficient, loosen the gear nut once and apply rust preventive oil or hypoid gear oil to the gear nut and to the screw or bearing surface of the driven pinion. Then perform the procedure again. If the tightening torque is less than the specified torque, replace the pinon bearing spacer with a new one and adjust it.
Do not loosen the pinion nut to reduce the preload.

INSTALL RING GEAR
1. Clean the contact surface of the ring gear and transfer ring gear mounting case.
  
  Fig 8: Heating Ring Gear In Boiling Water
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Heat the ring gear in boiling water.
3. Carefully remove the ring gear from the boiling water.
4. Align the matchmarks and quickly install the ring gear to the transfer ring gear mounting case.
  
  Fig 9: Locating Ring Gear Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. for Precoated Bolt:
  1. Apply adhesive to the 10 bolts.
    Adhesive
    
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
6. After the moisture on the ring gear has completely evaporated, install the 10 bolts.
  Precoated Bolt
  
  Torque: 112 N*m (1142 kgf*cm, 82 ft.*lbf)
  
  Uncoated Bolt
  
  Torque: 78 N*m (790 kgf*cm, 57 ft.*lbf)
  NOTE:
  - Tighten the bolts evenly in a diagonal pattern using several steps.
  - Tighten the bolts after the ring gear has cooled down sufficiently.
  - Confirm whether the bolts are precoated or uncoated as the tightening torque is different for each type.
  - In order to ensure proper sealing of the bolts, apply adhesive to the bolts and install them within 10 minutes of adhesive application.
INSTALL RING GEAR MOUNTING CASE BEARING
1. Using SST and a press, press the ring gear mounting case bearing (inner race) RH into the transfer ring gear mounting case.
  
  Fig 10: Installing Ring Gear Mounting Case Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00420
2. Install the ring gear mounting case bearing (outer race) RH to the transfer ring gear mounting case.
3. Apply gear oil to the ring gear mounting case bearing (inner race) RH.
4. Using SST and a press, press the ring gear mounting case bearing (inner race) LH into the transfer ring gear mounting case.
  
  Fig 11: Pressing Ring Gear Mounting Case Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09223-00010
  - SST: 09726-40010
5. Install the ring gear mounting case plate washer to the case.
  HINT:
  
  Use a new washer with the same thickness as the one removed when installing the bearing.
6. Using SST and a press, press the ring gear mounting case bearing (outer race) LH into the transfer case.
  
  Fig 12: Applying Gear Oil To Ring Gear Mounting Case Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00620
  - SST: 09950-70010
    - 09951-07200
7. Apply gear oil to the ring gear mounting case bearing (outer race).
INSTALL TRANSFER RING GEAR MOUNTING CASE
1. Apply gear oil to the transfer ring gear mounting case.
  
  Fig 13: Identifying Transfer Ring Gear Mounting Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transfer ring gear mounting case to the transfer case.
INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER
1. Align the cutout on a new No. 1 transfer output shaft spacer with the transfer case hole to install it as shown in the illustration.
  
  Fig 14: Aligning Cutout On No. 1 Transfer Output Shaft Spacer With Transfer Case Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER
1. Using a brass bar and a hammer, install a new No. 2 transfer ring gear mounting case washer.
  
  Fig 15: Installing No. 2 Transfer Ring Gear Mounting Case Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Install a new No. 2 washer with the same thickness as the one removed.
INSTALL BEARING CAP
1. Install the bearing cap with the 2 bolts.
  
  Fig 16: Locating Bearing Cap Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 63 N*m (644 kgf*cm, 47 ft.*lbf)

INSPECT RING GEAR BACKLASH

Set a dial indicator perpendicular to a ring gear tooth tip. Secure the driven pinion in place and move the ring gear back and forth to measure the backlash.

Fig 17: Inspecting Ring Gear Backlash
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Backlash

0.14 to 0.25 mm (0.00551 to 0.00984 in.)

NOTE:
Check at least 3 positions on the circumference of the ring gear.

If the backlash is outside the specified range, select a ring gear mounting case bearing LH side washer from the table and install it to meet the specified range.

Fig 18: Identifying Ring Gear Mounting Case Bearing LH Side Washer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WASHER THICKNESS: MM (IN.)

Mark	Thickness	Mark	Thickness
0F	2.05 (0.0807)	1N	2.57 (0.1012)
0G	2.07 (0.0815)	1P	2.59 (0.1020)
0H	2.09 (0.0823)	1Q	2.61 (0.1028)
0J	2.11 (0.0831)	1R	2.63 (0.1035)
0K	2.13 (0.0839)	1S	2.65 (0.1043)
0L	2.15 (0.0846)	1T	2.67 (0.1051)
0M	2.17 (0.0854)	1U	2.69 (0.1059)
0N	2.19 (0.0862)	1V	2.71 (0.1067)
0P	2.21 (0.0870)	1W	2.73 (0.1075)
0Q	2.23 (0.0878)	1X	2.75 (0.1083)
0R	2.25 (0.0886)	1Y	2.77 (0.1091)
0S	2.27 (0.0894)	1Z	2.79 (0.1098)
0T	2.29 (0.0902)	2F	2.81 (0.1106)
0U	2.31 (0.0910)	2G	2.83 (0.1114)
0V	2.33 (0.0917)	2H	2.85 (0.1122)
0W	2.35 (0.0925)	2J	2.87 (0.1130)
0X	2.37 (0.0933)	2K	2.89 (0.1138)
0Y	2.39 (0.0941)	2L	2.91 (0.1146)
0Z	2.41 (0.0949)	2M	2.93 (0.1154)
1F	2.43 (0.0957)	2N	2.95 (0.1161)
1G	2.45 (0.0965)	2P	2.97 (0.1169)
1H	2.47 (0.0972)	2Q	2.99 (0.1177)
1J	2.49 (0.0980)	2R	3.01 (0.1185)
1K	2.51 (0.0988)	2S	3.03 (0.1193)
1L	2.53 (0.0996)	2T	3.05 (0.1201)
1M	2.55 (0.1004)	2U	3.07 (0.1209)

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

Coat 3 or 4 teeth at the 4 different positions on the ring gear with red lead primer.

Fig 19: Applying Prussian Blue To Ring Gear Teeth
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Rotate the ring gear to inspect the tooth contact pattern.

Fig 20: Tooth Contact Pattern Chart
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the tooth contact pattern is not correct, select a new transfer output shaft washer that is thicker or thinner as necessary and recheck.

Fig 21: Identifying Transfer Output Shaft Washer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WASHER THICKNESS

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
AA	2.10 (0.0827)	JA	2.34 (0.0921)
AC	2.12 (0.0835)	JC	2.36 (0.0929)
BB	2.14 (0.0843)	KB	2.38 (0.0937)
CA	2.16 (0.0850)	LA	2.40 (0.0945)
CC	2.18 (0.0858)	LC	2.42 (0.0953)
DB	2.20 (0.0866)	MB	2.44 (0.0961)
EA	2.22 (0.0874)	NA	2.46 (0.0969)
EC	2.24 (0.0882)	NC	2.48 (0.0976)
FB	2.26 (0.0890)	PB	2.50 (0.0984)
GA	2.28 (0.0898)	QA	2.52 (0.0992)
GC	2.30 (0.0906)	QC	2.54 (0.1000)
HB	2.32 (0.0913)	-	-

NOTE:

When the washer thickness is changed, readjust the backlash. See step 2.

INSPECT AND ADJUST TOTAL PRELOAD

Using SST and a torque wrench, measure the total preload.

Fig 22: Measuring Total Preload

SST: 09326-20011

Total Preload (at Starting)

Item	Preload
New bearing (without SST)	0.39 to 0.59 Nm (4 to 6 kgfcm, 4 to 5 in.*lbf) + Driven pinion preload
New bearing (with SST)	0.28 to 0.43 Nm (3 to 4 kgfcm, 3 to 3.8 in.*lbf) + Driven pinion preload
Reused bearing (without SST)	0.25 to 0.49 Nm (3 to 4 kgfcm, 3 to 4 in.*lbf) + Driven pinion preload
Reused bearing (with SST)	0.18 to 0.35 Nm (2 to 3 kgfcm, 2 to 3 in.*lbf) + Driven pinion preload

HINT:

Use a torque wrench with a fulcrum length of 130 mm (5.12 in.).
Turn the driven pinion counterclockwise and clockwise several times.

If the preload is outside the specified range, replace the No. 2 transfer ring gear mounting case washer with one that is thicker or thinner as necessary and recheck.

Fig 23: Identifying No. 2 Transfer Ring Gear Mounting Case Washer

WASHER THICKNESS: MM (IN.)

Mark	Thickness	Mark	Thickness
G7	2.47 (0.0972)	M7	3.47 (0.1366)
G8	2.49 (0.0980)	M8	3.49 (0.1374)
G9	2.51 (0.0988)	M9	3.51 (0.1382)
H0	2.53 (0.0996)	N0	3.53 (0.1390)
H1	2.55 (0.1004)	N1	3.55 (0.1398)
H2	2.57 (0.1012)	N2	3.57 (0.1406)
H3	2.59 (0.1020)	N3	3.59 (0.1413)
H4	2.61 (0.1028)	N4	3.61 (0.1421)
H5	2.63 (0.1035)	N5	3.63 (0.1429)
H6	2.65 (0.1043)	N6	3.65 (0.1437)
H7	2.67 (0.1051)	N7	3.67 (0.1445)
H8	2.69 (0.1059)	N8	3.69 (0.1453)
H9	2.71 (0.1067)	N9	3.71 (0.1461)
J0	2.73 (0.1075)	P0	3.73 (0.1469)
J1	2.75 (0.1083)	P1	3.75 (0.1476)
J2	2.77 (0.1091)	P2	3.77 (0.1484)
J3	2.79 (0.1098)	P3	3.79 (0.1492)
J4	2.81 (0.1106)	P4	3.81 (0.1500)
J5	2.83 (0.1114)	P5	3.83 (0.1508)
J6	2.85 (0.1122)	P6	3.85 (0.1516)
J7	2.87 (0.1130)	P7	3.87 (0.1524)
J8	2.89 (0.1138)	P8	3.89 (0.1531)
J9	2.91 (0.1146)	P9	3.91 (0.1539)
K0	2.93 (0.1154)	Q0	3.93 (0.1547)
K1	2.95 (0.1161)	Q1	3.95 (0.1555)
K2	2.97 (0.1169)	Q2	3.97 (0.1563)
K3	2.99 (0.1177)	Q3	3.99 (0.1571)
K4	3.01 (0.1185)	Q4	4.01 (0.1579)
K5	3.03 (0.1193)	Q5	4.03 (0.1587)
K6	3.05 (0.1201)	Q6	4.05 (0.1594)
K7	3.07 (0.1209)	Q7	4.07 (0.1602)
K8	3.09 (0.1217)	Q8	4.09 (0.1610)
K9	3.11 (0.1224)	Q9	4.11 (0.1618)
L0	3.13 (0.1232)	R0	4.13 (0.1626)
L1	3.15 (0.1240)	R1	4.15 (0.1634)
L2	3.17 (0.1248)	R2	4.17 (0.1642)
L3	3.19 (0.1256)	R3	4.19 (0.1650)
L4	3.21 (0.1264)	R4	4.21 (0.1657)
L5	3.23 (0.1272)	R5	4.23 (0.1665)
L6	3.25 (0.1280)	R6	4.25 (0.1673)
L7	3.27 (0.1287)	R7	4.27 (0.1681)
L8	3.29 (0.1295)	R8	4.29 (0.1689)
L9	3.31 (0.1303)	R9	4.31 (0.1697)
M0	3.33 (0.1311)	S0	4.33 (0.1705)
M1	3.35 (0.1319)	S1	4.35 (0.1713)
M2	3.37 (0.1327)	S2	4.37 (0.1720)
M3	3.39 (0.1335)	S3	4.39 (0.1728)
M4	3.41 (0.1343)	S4	4.41 (0.1736)
M5	3.43 (0.1350)	S5	4.43 (0.1744)
M6	3.45 (0.1358)	S6	4.45 (0.1752)

Using a chisel and a hammer, stake the gear nut.

Fig 24: Staking Gear Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSFER CASE OIL SEAL RH (for RH Side)
1. Using SST and a hammer, drive a new transfer case oil seal RH into the case until it reaches the position shown in the illustration.
  
  Fig 25: Driving New Transfer Case Oil Seal RH Into Case Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00350
    - 09951-00580
    - 09952-06010
  - SST: 09950-70010
    - 09951-07150
  Drive in depth
  
  33.5 to 34.5 mm (1.319 to 1.358 in.)
  
  NOTE:
  Do not install the oil seal at an angle.
2. Apply a small amount of MP grease to the lip of the transfer case oil seal RH.
INSTALL TRANSFER CASE OIL SEAL
1. Using SST and a hammer, drive a new transfer case oil seal into the transfer case until it reaches the position shown in the illustration.
  
  Fig 26: Installing Transfer Case Front Oil Seal Into Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09608-10010
  - SST: 09950-70010
    - 09951-07150
  Drive in depth
  
  9.5 to 10.5 mm (0.374 to 0.413 in.)
2. Apply a small amount of MP grease to the lip of the transfer case oil seal.
INSTALL TRANSFER CASE REAR OIL SEAL
1. Using SST and a hammer, drive a new transfer case rear oil seal into the extension housing until it reaches the position shown in the illustration.
  
  Fig 27: Driving New Transfer Case Rear Oil Seal Into Extension Housing Using SST & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09325-20010
  Drive in depth
  
  1.1 to 1.9 mm (0.0433 to 0.0748 in.)
2. Apply a small amount of MP grease to the lip of the transfer case rear oil seal.
INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR
1. Using SST and a press, press in the extension housing dust deflector until it contacts the installation surface as shown in the illustration.
  - SST: 09950-60020
    - 09951-00810
  - SST: 09950-70010
    - 09951-07150
  Fig 28: Pressing In Extension Housing Dust Deflector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
1. Remove any FIPG material and be careful not to drop oil on the contact surfaces of the transfer extension housing sub-assembly and the transfer case.
  
  Fig 29: Applying FIPG To Transfer Extension Housing Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Degrease the surface with a non-residue solvent.
3. Apply FIPG to the transfer extension housing sub-assembly.
  FIPG
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
4. Install the transfer extension housing sub-assembly with the 4 bolts to the transfer case.
  
  Fig 30: Locating Transfer Extension Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
  
  NOTE:
  Assemble transfer extension housing sub-assembly within 10 minutes after the FIPG application.
SEPARATE TRANSFER ASSEMBLY
1. Remove the transfer assembly from the overhaul attachment.
INSTALL TRANSFER CASE STRAIGHT PIN
1. Using a plastic hammer, drive the 4 transfer case straight pins into the transfer case positions shown in the illustration.
  
  Fig 31: Locating Transfer Case Straight Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DYNAMIC DAMPER
1. Install the transfer dynamic damper with the 3 bolts to the transfer extension housing sub-assembly.
  
  Fig 32: Locating Transfer Dynamic Damper Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
INSTALL TRANSFER CASE BREATHER PLUG
1. Using SST and a hammer, tap in a new breather plug.
  
  Fig 33: Tapping In Breather Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09820-00031
INSTALL BREATHER OIL DEFLECTOR
1. Install the breather oil deflector with the bolt.
  
  Fig 34: Locating Breather Oil Deflector And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf)
INSTALL NO. 1 TRANSFER CASE COVER
1. Remove any FIPG material and be careful not to drop oil on the contact surfaces of the No. 1 transfer case cover and the transfer case.
  
  Fig 35: Applying FIPG To No. 1 Transfer Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Degrease the surface with a non-residue solvent.
3. Apply FIPG to the No. 1 transfer case cover.
  FIPG
  
  Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
4. Clean and degrease the 2 bolts (A) and the installation hole in the transfer case.
  
  Fig 36: Identifying No. 1 Transfer Case Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Apply adhesive to 2 or 3 threads on the ends of the bolt (A).
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
6. Install the No. 1 transfer case cover with the 8 bolts.
  Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
  NOTE:
  - Before pouring transfer oil, leave it at least an hour.
  - Assemble the No. 1 transfer case cover within 10 minutes after the FIPG application.
INSTALL TRANSFER DRAIN PLUG
1. Install a new gasket to the transfer drain plug.
  
  Fig 37: Locating Transfer Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transfer drain plug to the transfer assembly.
  Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
INSTALL NO. 1 TRANSFER CASE PLUG
1. Install a new gasket to the No. 1 transfer case plug.
  
  Fig 38: Locating No. 1 Transfer Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 transfer case plug to the transfer assembly.
  Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
INSTALL NO. 2 TRANSFER CASE PLUG
1. Install a new gasket to the No. 2 transfer case plug.
  
  Fig 39: Locating No. 2 Transfer Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 2 transfer case plug to the transfer assembly.
  Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT
1. Install the 4 transfer and transaxle setting stud bolts to the transfer case positions shown in the illustration.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  HINT:
  
  Install the shorter end of the stud bolts to the transfer.
  
  Fig 40: Locating Transaxle Setting Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Stud bolt length
  
  a
  
  30 mm (1.1811 in.)
  
  b
  
  12 mm (0.4724 in.)
  
  c
  
  22 mm (0.8661 in.)