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Transfer Assembly: Disassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. Remove the 4 transfer and transaxle setting stud bolts.
      Fig 1: Locating Transaxle Setting Stud Bolts
      GTY236008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 2 TRANSFER CASE PLUG 
    1. Remove the No. 2 transfer case plug.
      Fig 2: Locating No. 2 Transfer Case Plug
      GTY245327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the No. 2 transfer case plug.
  3. REMOVE NO. 1 TRANSFER CASE PLUG 
    1. Remove the No. 1 transfer case plug.
      Fig 3: Locating No. 1 Transfer Case Plug
      GTY212046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the No. 1 transfer case plug.
  4. REMOVE TRANSFER DRAIN PLUG 
    1. Remove the transfer drain plug.
      Fig 4: Locating Transfer Drain Plug
      GTY231907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the transfer drain plug.
  5. REMOVE TRANSFER CASE BREATHER PLUG 
    1. Using a screwdriver, remove the transfer case breather plug.
      Fig 5: Locating Transfer Case Breather Plug
      GTY138617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 1 TRANSFER CASE COVER 
    1. Remove the 8 bolts.
      Fig 6: Locating No. 1 Transfer Case Cover Bolts
      GTY242646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the No. 1 transfer case cover from the transfer case.
      Fig 7: Removing No. 1 Transfer Case Cover
      GTY226553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Place the brass bar on the rib protruding from the cover.

  7. REMOVE BREATHER OIL DEFLECTOR 
    1. Remove the bolt and breather oil deflector.
      Fig 8: Locating Breather Oil Deflector Bolt
      GTY242674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSFER DYNAMIC DAMPER 
    1. Remove the 3 bolts and transfer dynamic damper from the transfer extension housing sub-assembly.
      Fig 9: Locating Transfer Dynamic Damper Bolts
      GTY220314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 4 transfer case straight pins from the transfer case.
      Fig 10: Locating Transfer Case Straight Pins
      GTY244695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. SECURE TRANSFER ASSEMBLY 
    1. Attach the transfer assembly to the overhaul attachment.
  11. 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 11: Removing Transfer Extension Housing Dust Deflector
      GTY227909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE TRANSFER CASE REAR OIL SEAL 
    1. Using SST, remove the transfer case rear oil seal from the transfer extension housing sub-assembly.
      Fig 12: Removing Transfer Case Rear Oil Seal
      GTY243921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
      NOTE:

      Be careful not to damage the oil seal contact surface or the inside surface of the oil seal.

  13. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 4 bolts.
      Fig 13: Locating Transfer Extension Housing Bolts
      GTY244696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case.
      Fig 14: Removing Transfer Extension Housing Sub-Assembly
      GTY244697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT PRELOAD  See step  1
  15. INSPECT RING GEAR BACKLASH  See step  2
  16. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION  See step  3
  17. REMOVE TRANSFER CASE OIL SEAL 
    1. Using SST, remove the transfer case oil seal from the transfer case.
      Fig 15: Removing Transfer Case Front Oil Seal From Transfer Case
      GTY244698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
      NOTE:

      Do not damage the oil seal contact surface on the case.

  18. REMOVE TRANSFER CASE OIL SEAL RH 
    1. Using SST, remove the transfer case oil seal RH from the transfer case.
      Fig 16: Removing Transfer Case Front Oil Seal
      GTY243917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
      NOTE:

      Do not damage the oil seal contact surface on the case.

  19. REMOVE BEARING CAP 
    1. Remove the 2 bolts and bearing cap.
      Fig 17: Locating Bearing Cap Bolts
      GTY214833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER 
    1. Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer.
      Fig 18: Removing No. 1 Transfer Output Shaft Spacer
      GTY222294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09504-22011 
      NOTE:

      Do not damage the transfer case.

  21. REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER 
  22. REMOVE TRANSFER RING GEAR MOUNTING CASE 
    1. Remove the transfer ring gear mounting case from the transfer case.
      Fig 19: Identifying Transfer Ring Gear Mounting Case
      GTY242636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE DRIVEN PINION 
    1. Using SST and a hammer, unstake the gear nut.
      Fig 20: Unstaking Gear Nut
      GTY242755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09930-00010 

      HINT: 

      • Use SST with the flat side facing outward.
      • Do not machine the tip of SST with a grinder, etc.
    2. Using SST, remove the gear nut.
      Fig 21: Removing Gear Nut
      GTY223950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09326-20011 
      • SST: 09556-16030 
    3. Using a press, press out the driven pinion, transfer driven pinion rear bearing (inner race) and transfer pinion bearing spacer.
      Fig 22: Pressing Out Driven Pinion, Transfer Driven Pinion Rear Bearing (Inner Race) And Transfer Pinion Bearing Spacer
      GTY242640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Place a piece of cloth under the transfer case to prevent the driven pinion from dropping out of the bearing.
      • Use wooden blocks or similar objects under the case to keep it level.
  24. REMOVE TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST and a press, press out the transfer driven pinion front bearing (inner race).
      Fig 23: Pressing Out Front Transfer Driven Pinion Bearing
      GTY243915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-00020 
    2. Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the driven pinion front bearing (outer race) to remove it from the case.
      Fig 24: Removing Driven Pinion Front Bearing
      GTY242641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSFER OUTPUT SHAFT WASHER 
  26. REMOVE RING GEAR MOUNTING CASE BEARING 
    1. Remove the ring gear mounting case bearing (outer race) RH from the transfer ring gear mounting case.
    2. Using SST, remove the ring gear mounting case bearing (inner race) RH from the transfer ring gear mounting case.
      Fig 25: Removing Ring Gear Mounting Case Bearing (Inner Race) RH
      GTY242756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-40011 
        • 09951-04010
        • 09952-04010
        • 09953-04020
        • 09954-04010
        • 09955-04061
        • 09957-04010
        • 09958-04011
      • SST: 09950-60010 
        • 09951-00440
      NOTE:

      Use SST (09953-04020) after applying grease to its threads and tip.

    3. Using SST, remove the ring gear mounting case bearing (inner race) LH from the transfer ring gear mounting case.
      Fig 26: Removing Ring Gear Mounting (Inner Race) RH
      GTY242757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-40011 
        • 09951-04010
        • 09952-04010
        • 09953-04020
        • 09954-04010
        • 09955-04061
        • 09957-04010
        • 09958-04011
      • SST: 09950-60010 
        • 09951-00400
      NOTE:

      Use SST (09953-04020) after applying grease to its threads and tip.

    4. Using a brass bar and a hammer, tap the 2 positions shown in the illustration of the ring gear mounting case bearing (outer race) LH to remove it from the transfer case.
      Fig 27: Removing Ring Gear Mounting Case Bearing (Outer Race) LH
      GTY242647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the ring gear mounting case plate washer.
  27. INSPECT RING GEAR RUNOUT  See step  4
  28. REMOVE RING GEAR 
    1. Put matchmarks on the transfer ring gear mounting case and ring gear.
      Fig 28: Locating Ring Gear Bolts
      GTY219402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 10 bolts.
    3. Using a plastic hammer, tap on the ring gear to separate it from the transfer ring gear mounting case.
      Fig 29: Removing Ring Gear
      GTY228642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the ring gear teeth.

  29. INSPECT TRANSFER RING GEAR MOUNTING CASE  See step  5
  30. REMOVE TRANSFER DRIVEN PINION REAR BEARING 
    1. Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the driven pinion rear bearing (outer race) to remove it from the transfer case.
      Fig 30: Removing Driven Pinion Rear Bearing (Outer Race)
      GTY233817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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