TRANSFER ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL TRANSFER LOW PLANETARY RING GEAR


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

    2. A01XF7Z

      Using a screwdriver, install the snap ring.

  2. INSTALL PIN


    1. A01XHA6

      Install the pin.

  3. INSTALL COMPRESSION SPRING


    1. Install the spring.

  4. INSTALL TRANSFER CASE PLUG


    1. Install the transfer case plug.

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

  5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER


    1. A01XESB

      Install the washer.

  6. INSTALL TRANSFER DRIVE SPROCKET BEARING


    1. Install the bearing.

  7. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. Install the transfer drive sprocket.

  8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. Install the output shaft spacer.

  9. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING


    1. A01XKCZE01
      Text in Illustration
      *1 Groove
      B001CHY Rear

      Using SST and a press, install a new bearing.

      SST
      09316-60011   ( 09316-00011, 09316-00071 )

      Note

      Install the bearing so that the bearing snap ring groove faces the rear.

  10. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER


    1. A01XE15

      Install the washer.

  11. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING


    1. Install the needle roller bearing.

  12. INSTALL TRANSFER CLUTCH HUB


    1. Install the transfer clutch hub.

  13. INSTALL CENTER DIFFERENTIAL CASE


    1. A01XJIF

      Install the center differential case.

  14. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL


    1. Install the ball.

  15. INSTALL NO. 2 TRANSFER OUTPUT SHAFT SPACER


    1. Install the spacer.

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

  16. INSPECT DRIVE SPROCKET RADIAL CLEARANCE

    A01XMMP

    1. Using a dial indicator, measure the radial clearance of the drive sprocket.

      Standard clearance
      0.01 to 0.06 mm (0.000394 to 0.0236 in.)
      Maximum clearance
      0.06 mm (0.0236 in.)

      If the clearance is more than the maximum, replace the drive sprocket, rear output shaft or bearing.

  17. INSPECT DRIVE SPROCKET THRUST CLEARANCE

    A01XL0A

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

      Standard clearance
      0.15 to 0.24 mm (0.00591 to 0.00944 in.)
      Maximum clearance
      0.24 mm (0.00944 in.)

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

  18. INSTALL TRANSFER INPUT SHAFT BEARING


    1. A01XFRTE07

      Using SST and a press, install a new bearing with the groove facing forward.

      SST
      09223-15020
      09515-30010
      09950-70010   ( 09951-07100 )

  19. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING

    A01XGTB

    1. Select a new snap ring that allows minimal axial play.

      Standard Snap Ring Thickness
      Mark Specified Condition
      1 1.45 to 1.50 mm (0.0571 to 0.0591 in.)
      2 1.50 to 1.55 mm (0.0591 to 0.0610 in.)
      3 1.55 to 1.60 mm (0.0610 to 0.0630 in.)
      4 1.60 to 1.65 mm (0.0630 to 0.0650 in.)
      5 1.65 to 1.70 mm (0.0650 to 0.0669 in.)

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

  20. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE


    1. A01XJ7G

      Using a screwdriver, install the low planetary gear spline piece and snap ring.

  21. INSTALL TRANSFER LOW PLANETARY GEAR BEARING

    A01XEMEE07

    1. Using SST and a press, press in a new low planetary gear bearing.

      SST
      09950-60010   ( 09951-00570 )
      09950-70010   ( 09951-07100 )
      Press in depth
      7.7 to 8.3 mm (0.304 to 0.326 in.)

  22. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING


    1. A01XCZ5

      Apply gear oil to 2 new seal rings.

    2. Install the 2 seal rings to the input shaft.

      Note

      When installing the seal ring, make sure not to expand it so that its inner diameter exceeds 65 mm (2.55 in.).

  23. INSTALL TRANSFER LOW PLANETARY GEAR THRUST BEARING


    1. A01XELH

      Install the bearing.

      Text in Illustration
      B001CHY Front

  24. INSTALL NO. 1 TRANSFER THRUST BEARING RACE


    1. Install the thrust bearing race.

  25. INSTALL TRANSFER INPUT SHAFT


    1. Install the transfer input shaft.

  26. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER


    1. A01XLOU

      Install the washer.

  27. INSTALL TRANSFER INPUT GEAR STOPPER BALL


    1. Install the ball.

  28. INSTALL TRANSFER INPUT GEAR STOPPER


    1. Install the input gear stopper.

  29. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING


    1. A01XJCC

      Select a new input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.00197 to 0.00590 in.) of axial play.

      Standard Snap Ring Thickness
      Specified Condition
      2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      2.15 to 2.20 mm (0.0846 to 0.0866 in.)
      2.20 to 2.25 mm (0.0866 to 0.0886 in.)
      2.25 to 2.30 mm (0.0886 to 0.0906 in.)
      2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      2.35 to 2.40 mm (0.0925 to 0.0945 in.)
      2.40 to 2.45 mm (0.0945 to 0.0965 in.)
      2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      2.50 to 2.55 mm (0.0984 to 0.100 in.)
      2.55 to 2.60 mm (0.100 to 0.102 in.)
      2.60 to 2.65 mm (0.102 to 0.104 in.)
      2.65 to 2.70 mm (0.104 to 0.106 in.)
      2.70 to 2.75 mm (0.106 to 0.108 in.)
      2.75 to 2.80 mm (0.108 to 0.110 in.)
      2.80 to 2.85 mm (0.110 to 0.112 in.)
      2.85 to 2.90 mm (0.112 to 0.114 in.)
      2.90 to 2.95 mm (0.114 to 0.116 in.)
      2.95 to 3.00 mm (0.116 to 0.118 in.)
      3.00 to 3.05 mm (0.118 to 0.120 in.)
    2. A01XMFR

      Using a snap ring expander, install the snap ring.

  30. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT SUB-ASSEMBLY


    1. A01XCJ2

      Install the low planetary gear together with the input shaft.

    2. A01XM91

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

  31. INSTALL TRANSFER OIL PUMP GEAR


    1. A01XF3D

      Install the transfer oil pump gear.

  32. INSTALL TRANSFER OIL PUMP BODY O-RING


    1. A01XJN0

      Coat a new O-ring with gear oil and install it to the oil pump body.

  33. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY


    1. A01XIMS

      Install the oil pump body with the 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  34. INSTALL TRANSFER CASE MAGNET

  35. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY


    1. A01XGDK

      Install the oil separator with the 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  36. INSTALL FILLER PLUG


    1. Install a new gasket and the filler plug.

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

  37. INSTALL DRAIN PLUG


    1. Install a new gasket and the drain plug.

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

  38. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY


    1. A01XM4A

      Install a new O-ring to the transfer shift actuator assembly.

    2. A01XKYD

      Install the transfer shift actuator assembly with the 3 bolts.

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

    3. Using a screwdriver and hammer, tap on the 2 snap rings.

  39. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING


    1. A01XJOEE01

      Using SST and a press, install a new input gear radial ball bearing.

      SST
      09316-60011   ( 09316-00031 )

  40. INSTALL TRANSFER DRIVEN SPROCKET BEARING


    1. A01XCS7E01

      Using SST and a press, install a new driven sprocket bearing.

      SST
      09316-60011   ( 09316-00071 )

  41. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY


    1. A01XDL8

      Install the rear output shaft and drive sprocket to the front drive chain.

    2. A01XLJ8

      Install the rear output shaft, front drive chain and driven sprocket to the rear transfer case.

      Tech Tips

      Check that the rear output shaft and driven sprocket turn without much effort.

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

      Note

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

  42. INSTALL CENTER DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE


    1. A01XMI3

      Install the center differential lock fork and front drive clutch sleeve.

      Text in Illustration
      B001CHY Front

      Note

      Install the clutch sleeve in the correct direction.

    2. Install the bolt.

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

    3. Using a screwdriver and hammer, drive in the snap ring.

  43. INSTALL NO. 2 TRANSFER GEAR SHIFT FORK SUB-ASSEMBLY WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE


    1. A01XFGM

      Install the No. 2 gear shift fork and high and low clutch sleeve.

      Text in Illustration
      B001CHY Front

      Note

      Install the clutch sleeve in the correct direction.

    2. Install the bolt.

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

  44. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING


    1. Install the needle roller bearing to the input shaft.

  45. INSTALL TRANSFER OUTPUT SHAFT SPACER


    1. Install the transfer output shaft spacer to the input shaft.

  46. INSTALL REAR TRANSFER CASE


    1. A01XFYIE15
      Text in Illustration
      *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 is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the rear transfer case contact surface, 2) clean off any remaining old seal packing from the rear transfer case contact surface, and 3) reapply seal packing to the rear transfer case.

    2. A01XKFU

      Install the clamp and rear transfer case with the 12 bolts.

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

      Note

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

  47. INSTALL COLLAR


    1. A01XKUK

      Install the collar.

  48. INSTALL TRANSFER OUTPUT SHAFT WASHER


    1. Install the 2 washers.

  49. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY


    1. A01XHWVE12
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the extension housing as shown in the illustration.

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

      Note

      If the removed extension housing is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the housing contact surface, 2) clean off any remaining old seal packing from the housing contact surface, and 3) reapply seal packing to the housing.

    2. Apply adhesive to the threads of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A01XJSX

      Install the extension housing with the 5 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

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

  50. INSTALL TRANSFER CASE REAR OIL SEAL

    Click here

  51. INSTALL REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


    1. A01XKMSE08

      Using SST and a hammer, tap in a new oil seal.

      SST
      09950-60010   ( 09951-00320 )
      09950-70010   ( 09951-07100 )

    2. Coat the lip of the oil seal with MP grease.

  52. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. A01XMNIE01

      Apply gear oil to the connecting areas of the companion flange and output shaft.

    2. Install the companion flange to the output shaft.

      Text in Illustration
      B001CHY Rear

    3. Using SST to hold the companion flange, install a new lock nut.

      SST
      09330-00021
      Torque:
      118 N*m  { 1203 kgf*cm, 87 ft.*lbf }
    4. A01XEQUE10
      Text in Illustration
      *a Correct
      *b Incorrect

      Using a chisel and hammer, stake the lock nut.

      Note


      • Securely stake the shaft to the lock nut groove.

      • Be careful not to damage the parts around the lock nut.

      • Do not apply excessive force to the shaft.

  53. INSTALL TRANSFER CASE FRONT OIL SEAL

    Click here

  54. INSTALL FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


    1. A01XKMSE09

      Using SST and a hammer, tap in a new oil seal.

      SST
      09950-60010   ( 09951-00320 )
      09950-70010   ( 09951-07100 )

    2. Coat the lip of the oil seal with MP grease.

  55. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

    A01XEUME01

    1. Apply gear oil to the connecting areas of the companion flange and driven sprocket.

    2. Install the companion flange to the driven sprocket.

      Text in Illustration
      B001CHY Front

    3. Using SST to hold the companion flange, install a new lock nut.

      SST
      09330-00021
      Torque:
      118 N*m  { 1203 kgf*cm, 87 ft.*lbf }
    4. A01XEQUE11
      Text in Illustration
      *a Correct
      *b Incorrect

      Using a chisel and hammer, stake the lock nut.

      Note


      • Securely stake the shaft to the lock nut groove.

      • Be careful not to damage the parts around the lock nut.

      • Do not apply excessive force to the shaft.

  56. INSTALL BREATHER OIL DEFLECTOR


    1. Install the oil deflector.

  57. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY


    1. A01XFD9

      Install the case cover with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  58. INSTALL TRANSFER BEARING RETAINER OIL SEAL RH


    1. A01XCDDE07

      for A750F, AC60F, G52F, R150F:

      Using SST and a hammer, drive in a new transfer bearing retainer oil seal RH until its surface is flush with the retainer upper surface.

      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07100 )

    2. for RA61F:

      Using SST and a hammer, tap in 2 new transfer bearing retainer oil seals RH A and B as shown in the illustration.

      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07100 )

      1. A01XL5EE01
        Text in Illustration
        *1 Oil Seal A

        for oil seal A:

        Drive in depth (A)
        43 to 44 mm (1.70 to 1.73 in.)
      2. A01XCXRE01
        Text in Illustration
        *1 Oil Seal B

        for oil seal B:

        Drive in depth (B)
        53.5 to 54 mm (2.11 to 2.12 in.)

    3. Coat the lip of the transfer bearing retainer oil seal RH with MP grease.

  59. INSTALL TRANSFER BEARING RETAINER SUB-ASSEMBLY RH


    1. for RA61F:

      Install a new O-ring to the transfer bearing retainer sub-assembly RH.

      Note

      Apply MP grease to the O-ring when installing the transfer onto the transmission.

    2. A01XMJEE13
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the transfer bearing retainer sub-assembly RH as shown in the illustration.

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

      Note

      If the removed transfer bearing retainer sub-assembly RH is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the retainer contact surface, 2) clean off any remaining old seal packing from the retainer contact surface, and 3) reapply seal packing to the transfer bearing retainer sub-assembly RH.

    3. Apply sealant to the bolt threads.

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    4. A01XILM

      Install the transfer bearing retainer sub-assembly RH with the 5 bolts.

      Torque:
      12 N*m  { 117 kgf*cm, 8 ft.*lbf }

      Note

      Tighten the bolts of the transfer bearing retainer sub-assembly RH within 10 minutes of applying the seal packing. The seal packing will dry very quickly.

  60. INSTALL HOSE

    A01XEJT

    1. Attach the clamp and install the hose.