TRANSFER ASSEMBLY REASSEMBLY


  1. INSTALL TRANSFER DRIVEN PINION REAR BEARING


    1. A01EKOSE01

      Using SST and a press, press the transfer driven pinion rear bearing (outer race) into the transfer case.

      SST
      09950-60010   ( 09951-00620 )
      09950-70010   ( 09951-07150 )

      Note

      Keep the transfer case horizontal using wooden blocks, etc.

    2. Apply gear oil to the transfer driven pinion rear bearing (outer race).

  2. INSTALL TRANSFER OUTPUT SHAFT WASHER


    1. Install the transfer output shaft washer to the transfer case.

      Tech Tips

      Install the same transfer output shaft washer as the one removed.

    2. Apply gear oil to the transfer output shaft washer.

  3. INSTALL TRANSFER DRIVEN PINION FRONT BEARING


    1. A01EKZ2E03

      Apply gear oil to the inner surface of the transfer case.

    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 )
      09950-60020   ( 09951-00680 )
      Text in Illustration
      *1 Transfer Driven Pinion Front Bearing (Outer Race)
      *a Turn
      *b Hold
    3. A01ELI0E01

      Using SST and a press, press the transfer driven pinion front bearing (inner race) into the driven pinion.

      SST
      09506-30012

  4. INSTALL DRIVEN PINION


    1. A01EKXP

      Install the driven pinion to the transfer case.

    2. A01EK4Y

      Install a new transfer pinion bearing spacer and the transfer driven pinion rear bearing (inner race) to the driven pinion.

      Tech Tips

      Install the transfer pinion bearing spacer with the larger inner diameter facing forward as shown in the illustration.

    3. A01EKUBE01

      Using SST, install a new gear nut.

      SST
      09326-20011
      09556-16030
      Torque:
      without SST
      270 to 420 N*m  { 2753 to 4283 kgf*cm, 199 to 310 ft.*lbf }
      with SST
      254 to 396 N*m  { 2590 to 4038 kgf*cm, 187 to 292 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length of 840 mm (2.76 ft.).

      Note

      Do not stake the gear nut until the final preload, tooth contact and backlash adjustments are completed.

  5. ADJUST DRIVEN PINION PRELOAD


    1. A01ELWUE01

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

      SST
      09326-20011
      Preload (at Starting)
      Item Preload
      New bearing (without SST) 0.68 to 1.13 N*m (7 to 11 kgf*cm, 6 to 10 in.*lbf)
      New bearing (with SST) 0.49 to 0.81 N*m (5 to 8 kgf*cm, 5 to 7 in.*lbf)
      Reused bearing (without SST) 0.56 to 0.94 N*m (6 to 9 kgf*cm, 5 to 8 in.*lbf)
      Reused bearing (with SST) 0.40 to 0.67 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf)

      Tech Tips


      • Use a torque wrench with a fulcrum length of 130 mm (5.12 in.).

      • If the preload is more than the specification, replace the transfer pinion bearing spacer with a new one.

      • If the preload is not sufficient, adjust the driven pinion by tightening the gear 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 transfer pinion bearing spacer with a new one and adjust it.

      • Do not loosen the gear nut to reduce the preload.

  6. INSTALL RING GEAR


    1. A01EJMUE10
      Text in Illustration
      *a Boiling Water

      Clean the contact surfaces of the ring gear and transfer ring gear mounting case.

    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.

    5. for Seal Lock Bolt:


      1. Apply adhesive to whole threads and seat sections of 10 new bolts.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A01EKLYE03
      Text in Illustration
      *a Matchmark

      After the moisture on the ring gear has completely evaporated, install the 10 bolts.

      Torque:
      for Seal Lock Bolt
      112 N*m  { 1142 kgf*cm, 83 ft.*lbf }
      except Seal Lock Bolt
      78 N*m  { 795 kgf*cm, 58 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 (for Seal Lock Bolt) or uncoated (except Seal Lock Bolt) 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.

  7. INSTALL RING GEAR MOUNTING CASE BEARING


    1. A01EJPIE01

      Using SST and a press, press the ring gear mounting case bearing (inner race) into the transfer ring gear mounting case.

      SST
      09950-60010   ( 09951-00420 )

    2. Install the ring gear mounting case bearing (outer race) to the transfer ring gear mounting case.

    3. Apply gear oil to the ring gear mounting case bearing.

    4. A01EKFCE01

      Using SST and a press, press the ring gear mounting case bearing (inner race) into the transfer ring gear mounting case.

      SST
      09223-00010
      09726-40010

    5. Install the ring gear mounting case plate washer to the transfer case.

      Tech Tips

      If replacing the ring gear mounting case plate washer, use one with the same thickness as the one removed.

    6. A01EJCXE01

      Using SST and a press, press the ring gear mounting case bearing (outer race) into the transfer case.

      SST
      09950-60010   ( 09951-00620 )
      09950-70010   ( 09951-07200 )

    7. Apply gear oil to the ring gear mounting case bearing.

  8. INSTALL TRANSFER RING GEAR MOUNTING CASE


    1. A01EIMU

      Apply gear oil to the transfer ring gear mounting case.

    2. Install the transfer ring gear mounting case to the transfer case.

  9. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A01EKTJE03
      Text in Illustration
      *1 No. 1 Transfer Output Shaft Spacer
      *a Cutout
      *b Case Hole

      Align the cutout on the No. 1 transfer output shaft spacer with the transfer case hole to install it as shown in the illustration.

  10. INSTALL NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER


    1. A01EL6A

      Using a brass bar and a hammer, install the No. 2 transfer ring gear mounting case washer.

      Tech Tips

      If replacing the No. 2 transfer ring gear mounting case washer, use one with the same thickness as the one removed.

  11. INSTALL BEARING CAP


    1. A01EM8S

      Install the bearing cap with the 2 bolts.

      Torque:
      63 N*m  { 644 kgf*cm, 47 ft.*lbf }

  12. INSPECT RING GEAR BACKLASH


    1. A01ELNO

      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.

      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.

    2. A01EIYKE02
      Text in Illustration
      *1 Ring Gear Mounting Case Plate Washer

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

      Washer Thickness
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      5Q 1.95 (0.0768) 7N 2.67 (0.1051)
      5R 1.97 (0.0776) 7P 2.69 (0.1059)
      5S 1.99 (0.0783) 7Q 2.71 (0.1067)
      5T 2.01 (0.0791) 7R 2.73 (0.1075)
      5U 2.03 (0.0799) 7S 2.75 (0.1083)
      5V 2.05 (0.0807) 7T 2.77 (0.1091)
      5W 2.07 (0.0815) 7U 2.79 (0.1098)
      5X 2.09 (0.0823) 7V 2.81 (0.1106)
      5Y 2.11 (0.0831) 7W 2.83 (0.1114)
      5Z 2.13 (0.0839) 7X 2.85 (0.1122)
      6F 2.15 (0.0846) 7Y 2.87 (0.1130)
      6G 2.17 (0.0854) 7Z 2.89 (0.1138)
      6H 2.19 (0.0862) 8F 2.91 (0.1146)
      6J 2.21 (0.0870) 8G 2.93 (0.1154)
      6K 2.23 (0.0878) 8H 2.95 (0.1161)
      6L 2.25 (0.0886) 8J 2.97 (0.1169)
      6M 2.27 (0.0894) 8K 2.99 (0.1177)
      6N 2.29 (0.0902) 8L 3.01 (0.1185)
      6P 2.31 (0.0909) 8M 3.03 (0.1193)
      6Q 2.33 (0.0917) 8N 3.05 (0.1201)
      6R 2.35 (0.0925) 8P 3.07 (0.1209)
      6S 2.37 (0.0933) 8Q 3.09 (0.1217)
      6T 2.39 (0.0941) 8R 3.11 (0.1224)
      6U 2.41 (0.0949) 8S 3.13 (0.1232)
      6V 2.43 (0.0957) 8T 3.15 (0.1240)
      6W 2.45 (0.0965) 8U 3.17 (0.1248)
      6X 2.47 (0.0972) 8V 3.19 (0.1256)
      6Y 2.49 (0.0980) 8W 3.21 (0.1264)
      6Z 2.51 (0.0988) 8X 3.23 (0.1272)
      7F 2.53 (0.0996) 8Y 3.25 (0.1280)
      7G 2.55 (0.1004) 8Z 3.27 (0.1287)
      7H 2.57 (0.1012) 9D 3.29 (0.1295)
      7J 2.59 (0.1020) 9E 3.31 (0.1303)
      7K 2.61 (0.1028) 9F 3.33 (0.1311)
      7L 2.63 (0.1035) 9G 3.35 (0.1319)
      7M 2.65 (0.1043) 9H 3.37 (0.1327)

  13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION


    1. A01ELRJ

      Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.

    2. Turn the driven pinion to rotate the ring gear 10 times or more clockwise and 10 times or more counterclockwise.

    3. Rotate the ring gear to inspect the tooth contact pattern.

      A01EIPYE09
      Text in Illustration
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select a washer that will bring the driven pinion closer to the ring gear
      *e Toe Contact *f Flank Contact
      *g Select a washer that will shift the driven pinion away from the ring gear - -
    4. A01EJYHE02
      Text in Illustration
      *1 Transfer Output Shaft Washer

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

      Washer Thickness
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      ZA 2.00 (0.0787) KB 2.38 (0.0937)
      ZB 2.02 (0.0795) LA 2.40 (0.0945)
      ZC 2.04 (0.0803) LC 2.42 (0.0953)
      ZD 2.06 (0.0811) MB 2.44 (0.0961)
      ZE 2.08 (0.0819) NA 2.46 (0.0969)
      AA 2.10 (0.0827) NC 2.48 (0.0976)
      AC 2.12 (0.0835) PB 2.50 (0.0984)
      BB 2.14 (0.0843) QA 2.52 (0.0992)
      CA 2.16 (0.0850) QC 2.54 (0.1000)
      CC 2.18 (0.0858) RA 2.56 (0.1008)
      DB 2.20 (0.0866) RB 2.58 (0.1016)
      EA 2.22 (0.0874) RC 2.60 (0.1024)
      EC 2.24 (0.0882) SA 2.62 (0.1031)
      FB 2.26 (0.0890) SB 2.64 (0.1039)
      GA 2.28 (0.0898) SC 2.66 (0.1047)
      GC 2.30 (0.0906) TA 2.68 (0.1055)
      HB 2.32 (0.0913) TB 2.70 (0.1063)
      JA 2.34 (0.0921) TC 2.72 (0.1071)
      JC 2.36 (0.0929) - -

      Note

      When the washer thickness is changed, readjust the backlash Click here.

  14. INSPECT AND ADJUST TOTAL PRELOAD


    1. A01ELWUE01
      A01ELHOE02

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

      SST
      09326-20011
      Total Preload (at Starting)
      Item Preload
      New bearing (without SST) 0.48 to 0.70 N*m (5 to 7 kgf*cm, 5 to 6 in.*lbf) + Driven pinion preload
      New bearing (with SST) 0.35 to 0.50 N*m (4 to 5 kgf*cm, 4 to 4.4 in.*lbf) + Driven pinion preload
      Reused bearing (without SST) 0.35 to 0.53 N*m (4 to 5 kgf*cm, 4 to 4.6 in.*lbf) + Driven pinion preload
      Reused bearing (with SST) 0.25 to 0.38 N*m (3 to 3.8 kgf*cm, 3 to 3.3 in.*lbf) + Driven pinion preload

      Tech Tips


      • 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.

      Text in Illustration
      *1 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)
    2. A01EIRN

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

  15. INSTALL TRANSFER CASE FRONT OIL SEAL (for RH Side)


    1. A01EM6TE01

      Using SST and a hammer, drive a new transfer case front oil seal (for RH side) into the transfer case until it reaches the position shown in the illustration.

      SST
      09950-60010   ( 09951-00350, 09951-00580, 09952-06010 )
      09950-70010   ( 09951-07150 )
      Drive in depth
      33.5 to 34.5 mm (1.319 to 1.358 in.)

      Note

      Do not install the transfer case front oil seal (for RH side) at an angle.

    2. Apply a small amount of MP grease to the lip of the transfer case front oil seal (for RH side).

  16. INSTALL TRANSFER CASE FRONT OIL SEAL


    1. A01EKB1E01

      Using SST and a hammer, drive a new transfer case front oil seal into the transfer case until it reaches the position in the illustration.

      SST
      09608-10010
      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 front oil seal.

  17. INSTALL TRANSFER CASE REAR OIL SEAL


    1. A01ELIHE02

      Using SST and a hammer, drive a new transfer case rear oil seal into the transfer extension housing sub-assembly until it reaches the position shown in the illustration.

      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.

  18. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR


    1. A01EJXVE01

      Using SST and a press, press in a new transfer extension housing dust deflector until it contacts the installation surface as shown in the illustration.

      SST
      09950-60020   ( 09951-00810 )
      09950-70010   ( 09951-07150 )

  19. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY


    1. A01EJUQE03
      Text in Illustration
      *1 FIPG
      *a Seal Width 1.2 mm (0.0472 in.)

      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.

    2. Degrease the surfaces 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. A01EKXA

      Install the transfer extension housing sub-assembly with the 4 bolts to the transfer case.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

      Note

      Assemble the transfer extension housing sub-assembly within 10 minutes of FIPG application.

  20. SEPARATE TRANSFER ASSEMBLY


    1. Remove the transfer assembly from the overhaul attachment.

  21. 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.

      A01EKH4E01
      Text in Illustration
      *1 10.8 to 11.8 mm (0.425 to 0.465 in.) *2 5.7 to 6.7 mm (0.224 to 0.264 in.)

  22. INSTALL TRANSFER DYNAMIC DAMPER


    1. A01EKPW

      Install the transfer dynamic damper with the 3 bolts to the transfer extension housing sub-assembly.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

  23. INSTALL TRANSFER CASE BREATHER PLUG


    1. A01EMI8E01

      Using SST and a hammer, tap in a new transfer case breather plug.

      SST
      09820-00031

  24. INSTALL BREATHER OIL DEFLECTOR


    1. A01EMHW

      Install the breather oil deflector with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  25. INSTALL NO. 1 TRANSFER CASE COVER


    1. A01EJ5OE04
      Text in Illustration
      *1 FIPG
      *a Seal Width 1.2 mm (0.0472 in.)

      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.

    2. Degrease the surfaces 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. A01EIO4

      Install the No. 1 transfer case cover with the 6 bolts.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

      Note


      • Wait for at least 1 hour after installing the No. 1 transfer case cover before adding transfer oil.

      • Assemble the No. 1 transfer case cover within 10 minutes of FIPG application.

    5. A01EM7H

      Install the No. 1 transfer case cover with 2 new bolts.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

  26. INSTALL TRANSFER DRAIN PLUG


    1. A01ELX9

      Install a new gasket to the transfer drain plug.

    2. Install the transfer drain plug to the transfer assembly.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  27. INSTALL NO. 1 TRANSFER CASE PLUG


    1. A01EJGT

      Install a new gasket to the No. 1 transfer case plug.

    2. Install the No. 1 transfer case plug to the transfer assembly.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  28. INSTALL NO. 2 TRANSFER CASE PLUG


    1. A01EK0K

      Install a new gasket to the No. 2 transfer case plug.

    2. Install the No. 2 transfer case plug to the transfer assembly.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  29. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT


    1. Install 4 new transfer and transaxle setting stud bolts to the transfer case positions shown in the illustration.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Tech Tips

      Install the shorter end of the transfer and transaxle setting stud bolts to the transfer assembly.

      A01EKA1E02
      Text in Illustration
      *1 Transaxle Side *2 Transfer Side
      *3 30 mm (1.1811 in.) *4 12 mm (0.4724 in.)
      *5 22 mm (0.8661 in.) - -