TRANSFER ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL REAR TRANSFER DRIVEN PINION BEARING (OUTER RACE)


    1. A0028EVC02
      *1 Rear Transfer Driven Pinion Bearing (outer race)

      Using SST and a press, install the rear transfer driven pinion bearing (outer race) to the transfer case sub-assembly.

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

      Note


      • Keep the transfer case sub-assembly horizontal using wooden blocks, etc.

      • If the rear transfer driven pinion bearing (outer race) is damaged or deformed, replace it with a new one.

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

  2. INSTALL TRANSFER OUTPUT SHAFT WASHER


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

    2. Install the transfer output shaft washer to the transfer case sub-assembly.

      Note

      If the transfer output shaft washer is damaged or deformed, replace it with a new one.

      Tech Tips

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

  3. INSTALL FRONT TRANSFER DRIVEN PINION BEARING


    1. Apply gear oil to the inner surface of the transfer case sub-assembly.

    2. A0028FNC02
      *1 Transfer Output Shaft Washer
      *2 Front Transfer Driven Pinion Bearing (outer race)
      *a Turn
      *b Hold

      Using SST, install the front transfer driven pinion bearing (outer race) to the transfer case sub-assembly.

      SST
      09950-60010   ( 09951-00610, 09951-00620, 09951-00650 )
      09950-60020   ( 09951-00680 )

      Note


      • If the front transfer driven pinion bearing (outer race) is damaged or deformed, replace it with a new one.

      • When replacing the front transfer driven pinion bearing (outer race), replace both outer and inner races as one set.

    3. Apply gear oil to the front transfer driven pinion bearing (outer race).

    4. A002C1HN02

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

      SST
      09506-30012

      Note


      • If the front transfer driven pinion bearing (inner race) is damaged or deformed, replace it with a new one.

      • When replacing the front transfer driven pinion bearing (inner race), replace both outer and inner races as one set.

    5. Apply gear oil to the front transfer driven pinion bearing (inner race).

  4. INSTALL DRIVEN PINION


    1. A0026X6

      Install the driven pinion to the transfer case sub-assembly.

    2. A0027K0C01
      *1 Transfer Pinion Bearing Spacer
      *2 Rear Transfer Driven Pinion Bearing (inner race)
      *3 Gear Nut

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

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

      Note


      • If the rear transfer driven pinion bearing (inner race) is damaged or deformed, replace it with a new one.

      • When replacing the rear transfer driven pinion bearing (inner race), replace both outer and inner races as one set.

      Tech Tips

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

    4. Apply hypoid gear oil LSD to the threads of a new gear nut and its seating surface.

    5. A002CHDC02
      *a Torque Wrench Fulcrum Length

      Using SST, install the gear nut.

      SST
      09326-20011
      09556-16030
      Torque
      Specified tightening torque
      270 to 420 N*m (2753 to 4283 kgf*cm, 199 to 310 ft.*lbf)

      Note


      • This torque value is effective when SST is parallel to the torque wrench.

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

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 1100 mm (3.61 ft.)):

        258 to 402 N*m (2631 to 4099 kgf*cm, 190 to 296 ft.*lbf)

  5. ADJUST DRIVEN PINION PRELOAD


    1. A002793C01
      *a Torque Wrench Fulcrum Length

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

      SST
      09326-20011
      Preload (at Starting)
      Item Preload
      New bearing 0.7 to 1.4 N*m (7 to 14 kgf*cm, 6 to 12 in.*lbf)
      Reused bearing 0.5 to 0.9 N*m (5 to 9 kgf*cm, 4 to 8 in.*lbf)

      Note

      Turn the driven pinion counterclockwise and clockwise several times.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 130 mm (5.12 in.)):

        Specified Preload (at Starting)
        Item Preload
        New bearing 0.5 to 1.0 N*m (5 to 10 kgf*cm, 4 to 9 in.*lbf)
        Reused bearing 0.3 to 0.6 N*m (3 to 6 kgf*cm, 3 to 5 in.*lbf)

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

    3. 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.

    4. 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 LSD to the gear nut and to the screw or rear transfer driven pinion bearing (inner race) 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.

      Note

      Do not loosen the gear nut to reduce the preload.

  6. INSTALL RING GEAR


    1. A002BHUC05
      *a Boiling Water

      Heat the ring gear in boiling water.

    2. Secure the transfer ring gear mounting case in a vise using aluminum plates.

      Note


      • Be careful not to damage the transfer ring gear mounting case in the vise.

      • Remove any oil and water from the ring gear contact surface of the transfer ring gear mounting case.

      • Clean the bolt holes in the transfer ring gear mounting case.

    3. Carefully remove the ring gear from the boiling water.

      CAUTION:

      Make sure to wear protective gloves as the ring gear is extremely hot.

    4. A002B9XC02
      *a Matchmark

      After the moisture on the ring gear has completely evaporated, quickly align the matchmarks and set the ring gear to the transfer ring gear mounting case.

      Note

      There is no foreign matter on the contact surfaces of the transfer ring gear mounting case and ring gear.

    5. Apply adhesive to the bolt holes and contact surface of the 12 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


      • Apply adhesive after the ring gear has cooled down sufficiently.

      • Make sure to install the bolts immediately after applying adhesive to keep foreign matter away from them.

    6. Install the ring gear with the 12 bolts.

      Torque:
      98.6 N*m  { 1005 kgf*cm, 73 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.

  7. INSTALL RING GEAR MOUNTING CASE BEARING


    1. for LH side:


      1. A002C3NN01

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

        SST
        09223-00010
        09726-40010

        Note


        • If the ring gear mounting case bearing (inner race) is damaged or deformed, replace it with a new one.

        • When replacing the ring gear mounting case bearing (inner race), replace both outer and inner races as one set.

      2. Install the ring gear mounting case plate washer to the transfer case sub-assembly.

        Note

        If the ring gear mounting case plate washer is damaged or deformed, replace it with a new one.

        Tech Tips

        Use a new ring gear mounting case plate washer with the same thickness as the one removed when installing the ring gear mounting case bearing (outer race).

      3. A0029RUN01

        Using SST and a press, install the ring gear mounting case bearing (outer race) to the transfer case sub-assembly.

        SST
        09950-60010   ( 09951-00680 )
        09950-70010   ( 09951-07200 )

        Note


        • If the ring gear mounting case bearing (outer race) is damaged or deformed, replace it with a new one.

        • When replacing the ring gear mounting case bearing (outer race), replace both outer and inner races as one set.

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

    2. for RH side:


      1. A002BJ8N01

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

        SST
        09387-00010
        09950-70010   ( 09951-07100 )

        Note


        • If the ring gear mounting case bearing (inner race) is damaged or deformed, replace it with a new one.

        • When replacing the ring gear mounting case bearing (inner race), replace both outer and inner races as one set.

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

        Note


        • If the ring gear mounting case bearing (outer race) is damaged or deformed, replace it with a new one.

        • When replacing the ring gear mounting case bearing (outer race), replace both outer and inner races as one set.

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

  8. INSTALL TRANSFER RING GEAR MOUNTING CASE


    1. A00288A

      Install the transfer ring gear mounting case to the transfer case sub-assembly.

  9. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. Apply gear oil to the No. 1 transfer output shaft spacer.

    2. A002AQCC01
      *1 No. 1 Transfer Output Shaft Spacer
      *a Cutout
      *b Transfer Case Hole
      *c Transfer Case Sub-assembly

      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. Apply gear oil to the No. 2 transfer ring gear mounting case washer.

    2. A002A6E

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

      Tech Tips

      Use a No. 2 transfer ring gear mounting case washer with the same thickness as the one removed.

  11. INSTALL BEARING CAP


    1. A002CCB

      Install the bearing cap to the transfer case sub-assembly with the 2 bolts.

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

  12. INSPECT RING GEAR BACKLASH


    1. A002ANB

      Set a dial indicator perpendicular to a ring gear tooth tip.

    2. 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.

    3. A00280RC01
      *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 below and install it to meet the specified range.

      Tech Tips

      If the backlash is more than specified, select a thinner ring gear mounting case plate washer. If the backlash is less than specified, select a thicker ring gear mounting case plate washer.

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

  13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION


    1. A00297V

      Apply a light coat of Prussian blue evenly to both sides of all teeth.

    2. Rotate the ring gear 10 times or more.

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

      A002BXAC10
      *a Proper Contact *b Heel Contact
      *c Face Contact *d Select an adjusting washer that will shift the driven pinion closer to the ring gear (*b, *c)
      *e Toe Contact *f Flank Contact
      *g Select an adjusting washer that will shift the driven pinion away from the ring gear (*e, *f) - -

      Note

      Check at least 4 positions on the circumference of the ring gear.

      Tech Tips

      Prussian blue shown in the illustration indicates the tooth contact pattern.

    4. A0028OYC01
      *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.

      Note

      When the transfer output shaft washer thickness is changed, readjust the backlash.

      Click here

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

  14. INSPECT AND ADJUST TOTAL PRELOAD


    1. A002793C01
      *a Torque Wrench Fulcrum Length
      A002CJBC01
      *1 No. 2 Transfer Ring Gear Mounting Case Washer

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

      SST
      09326-20011
      Total Preload (at Starting)
      Item Preload
      New bearing 0.5 to 0.7 N*m (5 to 7 kgf*cm, 4 to 6 in.*lbf) + Driven pinion preload
      Reused bearing 0.4 to 0.5 N*m (4 to 5 kgf*cm, 3.5 to 4.4 in.*lbf) + Driven pinion preload

      Note

      Turn the driven pinion counterclockwise and clockwise several times.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 130 mm (5.12 in.)):

        Specified Total Preload (at Starting)
        Item Preload
        New bearing 0.4 to 0.5 N*m (4 to 5 kgf*cm, 3.5 to 4.4 in.*lbf) + Driven pinion preload
        Reused bearing 0.25 to 0.38 N*m (3 to 4 kgf*cm, 2 to 3 in.*lbf) + Driven pinion preload

      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.

      No. 2 Transfer Ring Gear Mounting Case Washer Thickness
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      G7 2.47 mm (0.0972 in.) M7 3.47 mm (0.1366 in.)
      G8 2.49 mm (0.0980 in.) M8 3.49 mm (0.1374 in.)
      G9 2.51 mm (0.0988 in.) M9 3.51 mm (0.1382 in.)
      H0 2.53 mm (0.0996 in.) N0 3.53 mm (0.1390 in.)
      H1 2.55 mm (0.1004 in.) N1 3.55 mm (0.1398 in.)
      H2 2.57 mm (0.1012 in.) N2 3.57 mm (0.1406 in.)
      H3 2.59 mm (0.1020 in.) N3 3.59 mm (0.1413 in.)
      H4 2.61 mm (0.1028 in.) N4 3.61 mm (0.1421 in.)
      H5 2.63 mm (0.1035 in.) N5 3.63 mm (0.1429 in.)
      H6 2.65 mm (0.1043 in.) N6 3.65 mm (0.1437 in.)
      H7 2.67 mm (0.1051 in.) N7 3.67 mm (0.1445 in.)
      H8 2.69 mm (0.1059 in.) N8 3.69 mm (0.1453 in.)
      H9 2.71 mm (0.1067 in.) N9 3.71 mm (0.1461 in.)
      J0 2.73 mm (0.1075 in.) P0 3.73 mm (0.1469 in.)
      J1 2.75 mm (0.1083 in.) P1 3.75 mm (0.1476 in.)
      J2 2.77 mm (0.1091 in.) P2 3.77 mm (0.1484 in.)
      J3 2.79 mm (0.1098 in.) P3 3.79 mm (0.1492 in.)
      J4 2.81 mm (0.1106 in.) P4 3.81 mm (0.1500 in.)
      J5 2.83 mm (0.1114 in.) P5 3.83 mm (0.1508 in.)
      J6 2.85 mm (0.1122 in.) P6 3.85 mm (0.1516 in.)
      J7 2.87 mm (0.1130 in.) P7 3.87 mm (0.1524 in.)
      J8 2.89 mm (0.1138 in.) P8 3.89 mm (0.1531 in.)
      J9 2.91 mm (0.1146 in.) P9 3.91 mm (0.1539 in.)
      K0 2.93 mm (0.1154 in.) Q0 3.93 mm (0.1547 in.)
      K1 2.95 mm (0.1161 in.) Q1 3.95 mm (0.1555 in.)
      K2 2.97 mm (0.1169 in.) Q2 3.97 mm (0.1563 in.)
      K3 2.99 mm (0.1177 in.) Q3 3.99 mm (0.1571 in.)
      K4 3.01 mm (0.1185 in.) Q4 4.01 mm (0.1579 in.)
      K5 3.03 mm (0.1193 in.) Q5 4.03 mm (0.1587 in.)
      K6 3.05 mm (0.1201 in.) Q6 4.05 mm (0.1594 in.)
      K7 3.07 mm (0.1209 in.) Q7 4.07 mm (0.1602 in.)
      K8 3.09 mm (0.1217 in.) Q8 4.09 mm (0.1610 in.)
      K9 3.11 mm (0.1224 in.) Q9 4.11 mm (0.1618 in.)
      L0 3.13 mm (0.1232 in.) R0 4.13 mm (0.1626 in.)
      L1 3.15 mm (0.1240 in.) R1 4.15 mm (0.1634 in.)
      L2 3.17 mm (0.1248 in.) R2 4.17 mm (0.1642 in.)
      L3 3.19 mm (0.1256 in.) R3 4.19 mm (0.1650 in.)
      L4 3.21 mm (0.1264 in.) R4 4.21 mm (0.1657 in.)
      L5 3.23 mm (0.1272 in.) R5 4.23 mm (0.1665 in.)
      L6 3.25 mm (0.1280 in.) R6 4.25 mm (0.1673 in.)
      L7 3.27 mm (0.1287 in.) R7 4.27 mm (0.1681 in.)
      L8 3.29 mm (0.1295 in.) R8 4.29 mm (0.1689 in.)
      L9 3.31 mm (0.1303 in.) R9 4.31 mm (0.1697 in.)
      M0 3.33 mm (0.1311 in.) S0 4.33 mm (0.1705 in.)
      M1 3.35 mm (0.1319 in.) S1 4.35 mm (0.1713 in.)
      M2 3.37 mm (0.1327 in.) S2 4.37 mm (0.1720 in.)
      M3 3.39 mm (0.1335 in.) S3 4.39 mm (0.1728 in.)
      M4 3.41 mm (0.1343 in.) S4 4.41 mm (0.1736 in.)
      M5 3.43 mm (0.1350 in.) S5 4.43 mm (0.1744 in.)
      M6 3.45 mm (0.1358 in.) S6 4.45 mm (0.1752 in.)
    2. A00296Q

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

  15. INSTALL TRANSFER CASE OIL SEAL RH


    1. A002B4FC02
      *1 Transfer Case Oil Seal RH
      *a Depth

      Using SST and a hammer, install a new transfer case oil seal RH to the transfer case sub-assembly until it reaches the position shown in the illustration.

      SST
      09950-60010   ( 09951-00340, 09951-00580, 09952-06010 )
      09950-70010   ( 09951-07150 )
      Standard Depth
      33.5 to 34.5 mm (1.32 to 1.36 in.)

      Note


      • Make sure that the transfer case oil seal RH is not tilted.

      • Do not tap in the transfer case oil seal RH in too far.

    2. Coat the lip of the transfer case oil seal RH with MP grease.

  16. INSTALL TRANSFER CASE OIL SEAL


    1. A002B94C01
      *1 Transfer Case Oil Seal
      *a Depth

      Using SST and a hammer, install a new transfer case oil seal to the transfer case sub-assembly until it reaches the position shown in the illustration.

      SST
      09608-10010
      09950-70010   ( 09951-07150 )
      Standard Depth
      9.5 to 10.5 mm (0.374 to 0.413 in.)

      Note


      • Make sure that the transfer case oil seal is not tilted.

      • Do not tap in the transfer case oil seal in too far.

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

  17. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL


    1. A0028QPC01
      *1 Transfer Extension Housing Type T Oil Seal
      *a Depth

      Using SST and a hammer, install a new transfer extension housing type T oil seal to the transfer extension housing sub-assembly until it reaches the position shown in the illustration.

      SST
      09325-20010
      Standard Depth
      9.8 to 10.6 mm (0.386 to 0.417 in.)

      Note


      • Make sure that the transfer extension housing type T oil seal is not tilted.

      • Do not tap in the transfer extension housing type T oil seal in too far.

    2. Coat the lip of the transfer extension housing type T oil seal with MP grease.

  18. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR


    1. A00288EC01
      *a Rib
      *b Approximately 1 to 2 mm (0.0394 to 0.0787 in.)

      Using SST and a press, install a new transfer extension housing dust deflector to the transfer extension housing sub-assembly so that the clearance between the rib of the transfer extension housing sub-assembly and the transfer extension housing dust deflector is approximately 1 to 2 mm (0.0394 to 0.0787 in.).

      SST
      09950-60020   ( 09951-01030 )
      09950-70010   ( 09951-07150 )
    2. A002857C01
      *a Rib

      Using SST and a hammer, tap in the transfer extension housing dust deflector until it contacts the rib of the transfer extension housing sub-assembly.

      SST
      09950-60020   ( 09951-01030 )
      09950-70010   ( 09951-07150 )

      Note

      Make sure that the transfer extension housing dust deflector evenly contacts the 3 ribs of the transfer extension housing sub-assembly.

  19. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY


    1. Remove any FIPG and be careful not to drop oil on the contact surfaces of the transfer extension housing sub-assembly and transfer case sub-assembly.

    2. Degrease the surfaces with a non-residue solvent.

    3. A0029UAC01
      *a FIPG

      Apply FIPG to the transfer extension housing sub-assembly.

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

      Note


      • Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface of the transfer extension housing sub-assembly.

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

    4. A002AAY

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

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

  20. REMOVE TRANSFER ASSEMBLY


    1. Remove the transfer assembly from the overhaul attachment.

  21. INSTALL TRANSFER CASE STRAIGHT PIN


    1. Using a plastic hammer, install the 4 transfer case straight pins to the transfer case sub-assembly at the positions shown in the illustration.

      A0026V5C01
      *a 10.8 to 11.8 mm (0.425 to 0.465 in.) *b 5.7 to 6.7 mm (0.224 to 0.264 in.)

  22. INSTALL BREATHER OIL DEFLECTOR


    1. A0029YN

      Install the breather oil deflector to the transfer case cover sub-assembly with the bolt.

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

      Note

      Make sure that the breather oil deflector is installed in the correct direction.

  23. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY


    1. Remove any FIPG and be careful not to drop oil on the contact surfaces of the transfer case cover sub-assembly and transfer case sub-assembly.

    2. Degrease the surfaces with a non-residue solvent.

    3. A0027RQC01
      *a FIPG

      Apply FIPG to the transfer case cover sub-assembly.

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

      Note


      • Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface of the transfer case cover sub-assembly.

      • Assemble the transfer case cover sub-assembly within 10 minutes after the FIPG application.

    4. A002ANY

      Install the transfer case cover sub-assembly to the transfer case sub-assembly with the 6 bolts.

      Torque:
      19.6 N*m  { 200 kgf*cm, 14 ft.*lbf }
    5. A002A71

      Install 2 new bolts.

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

      Note

      Wait for at least 1 hour after installing the transfer case cover sub-assembly before adding transfer oil.

  24. INSTALL TRANSFER CASE BREATHER PLUG


    1. A002BR3N03

      Using SST and a hammer, install a new transfer case breather plug to the transfer case cover sub-assembly.

      SST
      09612-10093   ( 09612-10061 )

  25. INSTALL TRANSFER DRAIN PLUG


    1. Install a new gasket to the transfer drain plug.

    2. A002AJ4

      Install the transfer drain plug to the transfer case sub-assembly.

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

  26. INSTALL NO. 1 TRANSFER CASE PLUG


    1. A0026YJ

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

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

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

  27. INSTALL NO. 2 TRANSFER CASE PLUG


    1. A0029MM

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

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

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

  28. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT


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

      A0026Z5C01
      *a Automatic Transaxle Assembly Side *b Transfer Case Sub-assembly Side
      *c 30 mm (1.18 in.) *d 22 mm (0.866 in.)
      *e 64 mm (2.52 in.) - -
      Torque:
      Transfer and Transaxle Setting Stud Bolt (A)
      39.2 N*m  { 400 kgf*cm, 29 ft.*lbf }
      Transfer and Transaxle Setting Stud Bolt (B)
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Install the sealed side of the transfer and transaxle setting stud bolt to the transfer case sub-assembly.