TRANSFER ASSEMBLY REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

PROCEDURE


  1. INSTALL REAR TRANSFER OUTPUT SHAFT


    1. A01XBPL

      Install a new needle roller bearing.

    2. A01X2YQE01

      Using SST and a press, press in a new bearing.

      SST
      09527-10011

      Note

      Set the snap ring groove of the bearing to the front side.

  2. INSTALL TRANSFER DRIVE SPROCKET BEARING


    1. A01X7W6

      Install the bearing to the output shaft.

  3. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. A01X95N

      Install the drive sprocket to the output shaft.

  4. INSTALL TRANSFER OUTPUT SHAFT SPACER


    1. A01X0UJE01
      *1 Straight Pin

      Install the straight pin to the output shaft.

    2. A01WZJY

      Align the straight pin with the straight pin groove of the output shaft spacer, and slide on the output shaft spacer.

    3. A01XBNL

      Using a screwdriver and hammer, tap on the snap ring.

  5. INSPECT TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. A01X9XQ

      Using a feeler gauge, measure the drive sprocket thrust clearance.

      Standard Clearance
      0.10 to 0.47 mm (0.00394 to 0.0185 in.)
      Maximum Clearance
      0.47 mm (0.0185 in.)

      If the clearance is more than the maximum, replace the drive sprocket sub-assembly.

  6. INSTALL CENTER DIFFERENTIAL CASE


    1. A01X5WIE01

      Using SST and a hammer, tap in a new needle roller bearing until its surface is 0 to 0.5 mm (0 to 0.0197 in.) from the center differential case upper surface.

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

      Note


      • Be careful not to damage the center differential case.

      • Install the bearing so that the mark is on the outside.

    2. A01X2WAE01

      Using SST and a hammer, tap in a new needle roller bearing until its surface is 1.5 to 2.0 mm (0.0591 to 0.0787 in.) from the center differential case upper surface.

      SST
      09950-60010   ( 09951-00460 )
      09950-70010   ( 09951-07100 )

      Note


      • Be careful not to damage the center differential case.

      • Install the bearing so that the mark is on the outside.

    3. A01X584E03
      *1 Synchromesh Shifting Key Spring
      *2 No. 2 Synchromesh Shifting Key

      for Manual Transmission:

      Install the synchromesh shifting key spring and No. 2 synchromesh shifting keys as shown in the illustration.

    4. A01WZUZ

      for Manual Transmission:

      Using a snap ring expander, install the snap ring.

    5. A01X98O

      Install the center differential case to the output shaft.

  7. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A01XAANE01
      *1 Straight Pin

      Install the straight pin to the output shaft.

    2. A01X2TK

      Install a new seal ring to the output shaft spacer.

    3. A01X1R4

      Align the pin with the straight pin groove of the output shaft spacer, and slide on the output shaft spacer.

    4. A01WZHH

      Using a screwdriver and hammer, tap on the snap ring.

  8. INSTALL TRANSFER OUTPUT SHAFT WASHER


    1. A01X9C2

      Install the 2 output shaft washers to the output shaft.

  9. INSTALL TRANSFER INPUT SHAFT PLUG


    1. A01X5CFE01

      Using SST and a hammer, tap in a new input shaft plug until its surface is 1.0 to 1.8 mm (0.0394 to 0.0709 in.) from the input shaft upper surface.

      SST
      09950-60010   ( 09951-00410 )
      09950-70010   ( 09951-07150 )

      Note

      Be careful not to damage or deform the input shaft plug when tapping it.

  10. INSTALL TRANSFER INPUT SHAFT BIMETAL FORMED BUSH


    1. A01WYV1E01

      Using SST and a hammer, tap in a new bush until its surface is 5.5 to 5.9 mm (0.217 to 0.232 in.) from the input shaft upper surface.

      SST
      09950-70010   ( 09951-07150 )
      09950-60010   ( 09951-00610 )

      Note

      Be careful not to damage the input shaft.

  11. INSTALL TRANSFER INPUT SHAFT BEARING


    1. A01X8PUE01
      *1 Temper Color Side

      Install the low planetary gear bearing and low planetary gear to the input shaft.

      Note


      • Make sure the low planetary gear bearing is installed in the correct direction.

      • Install the low planetary gear bearing so that its temper color side faces the low planetary gear.

    2. A01XC3FE01
      *1 Temper Color Side

      Install the low planetary gear bearing and a new input shaft bearing to the input shaft.

      Note


      • Make sure the input shaft bearing is installed in the correct direction.

      • Make sure the low planetary gear bearing is installed in the correct direction.

      • Install the low planetary gear bearing so that its temper color side faces the low planetary gear.

    3. A01WYXME01

      Using SST and a press, press in the bearing.

      SST
      09513-36040
      09515-21010

      Note

      After press-fitting the bearing to the input shaft, check that the bearing moves smoothly.

    4. A01X7BZ

      Select a snap ring that allows for minimum axial play and install it to the shaft.

      Standard Snap Ring Thickness
      Mark Specified Condition
      C 2.13 to 2.18 mm (0.0839 to 0.0858 in.)
      D 2.18 to 2.23 mm (0.0858 to 0.0878 in.)
      E 2.23 to 2.28 mm (0.0878 to 0.0898 in.)
      F 2.28 to 2.33 mm (0.0898 to 0.0917 in.)
      G 2.33 to 2.38 mm (0.0917 to 0.0937 in.)
      H 2.38 to 2.43 mm (0.0937 to 0.0957 in.)
      J 2.43 to 2.48 mm (0.0957 to 0.0976 in.)

    5. Using a snap ring expander, install the snap ring.

      Note

      Make sure that the snap ring is firmly installed to the groove.

  12. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING

    A01X8Y7E01
    *1 Seal Ring

    1. Apply transfer oil to a new seal ring.

    2. Install a new seal ring to the input shaft.

  13. INSTALL TRANSFER DRIVEN SPROCKET BEARING


    1. A01X6VI

      Install a new bearing to the front transfer case in the direction shown in the illustration.

      Note

      Make sure the bearing is installed in the correct direction.

    2. A01XA1F

      Using a screwdriver, install the snap ring.

  14. INSTALL TRANSFER LOW PLANETARY RING GEAR


    1. A01X7YX

      Using a snap ring expander, install the snap ring to the front transfer case.

    2. A01X00CE01
      *1 Front

      Install the low planetary ring gear to the front transfer case.

      Note

      Make sure to install the low planetary ring gear in the correct direction.

    3. A01X0WQ

      Using a screwdriver, install the snap ring.

      Note

      Make sure that the snap ring is firmly installed to the groove.

  15. INSTALL INPUT SHAFT ASSEMBLY


    1. A01X5FI

      While expanding the snap ring, install the input shaft to the front transfer case.

    2. Apply adhesive to the threads of the 2 case plugs.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Install the plugs within 3 minutes of application.

    3. A01X483

      Using a 14 mm hexagon wrench, install the 2 case plugs.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  16. INSTALL TRANSFER CASE MAGNET


    1. A01X8EH

      Install the magnet to the oil separator.

  17. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY


    1. Install a new O-ring to the oil separator.

    2. A01X266

      Install the oil separator with the 3 bolts.

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }

  18. INSTALL SIDE GEAR SHAFT HOLDER BEARING


    1. A01X2FUE01

      Using SST and a hammer, tap in a new bearing to the rear transfer case.

      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07100 )
    2. A01XAFZ

      Using a screwdriver, install the snap ring.

  19. INSTALL FRONT DRIVE CLUTCH SLEEVE

    A01X4TKE01
    *1 Front

    1. Apply gear oil to the connecting areas of the clutch sleeve and center differential case.

    2. Install the clutch sleeve onto the output shaft.

      Note

      Make sure that the clutch sleeve is installed facing the correct direction.

  20. INSTALL REAR TRANSFER OUTPUT SHAFT ASSEMBLY


    1. A01X8BC

      Install the snap ring to the rear transfer case.

    2. A01X6MJE01
      *1 Drive Chain
      *2 Driven Sprocket
      *3 Output Shaft

      Install the output shaft, drive chain and driven sprocket.

      Note

      Do not drop the output shaft washers.

    3. A01X94G

      Using a snap ring expander, install the snap ring to the output shaft.

      Note

      Make sure that the snap ring is firmly installed to the groove.

  21. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY


    1. A01XARWE05
      *1 O-Ring

      Install a new O-ring to the shift actuator.

    2. A01WZV2E02
      *1 Shift Actuator
      *2 No. 1 Transfer Gear Shift Fork

      Set the No. 1 gear shift fork to the front drive clutch sleeve.

    3. A01X23L

      Install the shift actuator to the rear transfer case with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    4. A01XBOT

      Install the No. 1 gear shift fork to the shift actuator with the bolt.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  22. INSTALL NO. 2 TRANSFER GEAR SHIFT FORK


    1. A01X7T0E01
      *1 Front

      Set the No. 2 gear shift fork together with the high and low clutch sleeve to the shift actuator.

    2. A01X6G3

      Install the No. 2 gear shift fork to the shift actuator with the bolt.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
    3. A01X8IX

      Using a screwdriver and hammer, tap the 4 shift fork shaft snap rings onto the shift fork shaft.

  23. INSTALL FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING


    1. A01X978E06
      *1 Needle Roller Bearing
      *2 Spacer

      Install the needle roller bearing and spacer to the output shaft.

  24. INSTALL NO. 1 SYNCHRONIZER RING (for Manual Transmission)

    A01X00B

    1. Align the protrusion of the synchronizer ring with the notch on the differential case and install it.

  25. INSTALL REAR TRANSFER CASE ASSEMBLY


    1. A01XAXPE01
      *1 Seal Packing

      Apply seal packing to the rear transfer case as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Note

      If the removed rear transfer case will be reused: After removing the rear transfer case, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old FIPG on the rear transfer case contact surface, 2) clean off any remaining old FIPG from the rear transfer case contact surface, and 3) reapply seal packing to the rear transfer case.

    2. A01X0M2

      Install the rear transfer case with the 14 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note

      Tighten the bolts within 10 minutes of applying the seal packing. The seal packing will dry very quickly.

  26. INSTALL TRANSFER CASE PLUG


    1. Apply adhesive to the threads of the plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Install the plug within 3 minutes of application.

    2. A01X4QB

      Using a 6 mm hexagon wrench, install the plug.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  27. INSTALL NO. 1 TRANSFER CASE PLUG


    1. A01X5JX

      Install the pin and compression spring to the front transfer case.

    2. Apply adhesive to the threads of the plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Install the plug within 3 minutes of application.

    3. Install the plug.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  28. INSTALL TRANSFER CASE REAR OIL SEAL

    Click here

  29. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Install the companion flange onto the output shaft.

    2. A01WZUHE04

      Using SST to hold the companion flange, install a new O-ring and a new companion flange lock nut.

      SST
      09330-00021
      Torque:
      112 N*m  { 1137 kgf*cm, 82 ft.*lbf }
    3. A01X2PFE01
      *1 CORRECT
      *2 INCORRECT

      Using a chisel and hammer, stake the companion flange lock nut.

  30. INSTALL TRANSFER CASE FRONT OIL SEAL

    Click here

  31. INSTALL TRANSFER OUTPUT SHAFT DUST DEFLECTOR


    1. A01X64YE01

      Using SST and a press, install a new transfer output shaft dust deflector.

      SST
      09523-36010
      09950-60010   ( 09951-00460, 09951-00560, 09952-06010 )
      09950-70010   ( 09951-07100 )

      Note


      • Be careful not to damage the transfer output shaft dust deflector and front output shaft companion flange sub-assembly.

      • The transfer output shaft dust deflector should be installed completely.

    2. A01X9ARE01

      Apply MP grease to the transfer output shaft dust deflector lip.

      Standard Grease Capacity
      Location A
      0.4 to 0.6 g (0.015 to 0.021 oz.)
      Location B
      0.1 g (0.0004 oz.)

  32. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Install the companion flange onto the drive sprocket.

    2. A01XBGME01

      Using SST to hold the companion flange, install a new O-ring and a new companion flange lock nut.

      SST
      09330-00021
      Torque:
      112 N*m  { 1137 kgf*cm, 82 ft.*lbf }
    3. A01X2PFE01
      *1 CORRECT
      *2 INCORRECT

      Using a chisel and hammer, stake the companion flange lock nut.

  33. INSTALL TRANSFER OIL PUMP PLATE OIL SEAL


    1. A01X2N4E01

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump plate upper surface.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07100 )

      Note

      Be careful not to damage the oil pump plate.

  34. INSTALL TRANSFER CASE PLUG


    1. A01X9YI

      Install the relief valve seat, ball and compression spring to the oil pump plate.

    2. Apply adhesive to the threads of the plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Install the plug within 3 minutes of application.

    3. Using a 10 mm hexagon wrench, install the plug.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  35. INSTALL TRANSFER CASE STRAIGHT PIN


    1. A01XAUTE04
      *1 Transfer Case Straight Pin

      Install the 2 straight pins to the input shaft.

  36. INSTALL TRANSFER OIL PUMP PLATE


    1. Apply transfer oil to a new O-ring, drive rotor, driven rotor and a new transfer oil seal ring.

    2. A01X0TDE06
      *1 Oil Pump Drive Rotor

      Install the drive rotor to the input shaft.

    3. A01X9G5

      Install the transfer oil seal ring to the input shaft.

    4. Install the O-ring to the oil pump plate.

    5. A01X981

      Install the oil pump plate and driven rotor to the front transfer case with the 4 bolts.

      Torque:
      12 N*m  { 117 kgf*cm, 9 ft.*lbf }

  37. INSTALL PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY


    1. A01XA26

      Install the bracket to the rear transfer case with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }