TRANSFER ASSEMBLY REASSEMBLY

PROCEDURE


  1. INSTALL TRANSFER DRIVE CLUTCH HUB


    1. B006998N01

      Using SST and a press, install a new transfer drive clutch hub.

      SST
      09527-10011

      Note


      • When replacing the transfer drive clutch hub, replace it with a new one and align it with the rear transfer output shaft.

      • Make sure the transfer drive clutch hub contacts the edge of the rear transfer output shaft, but do not press it in more than necessary.

  2. INSTALL FRONT DRIVE CLUTCH SLEEVE


    1. w/ A.D.D.:


      1. B0068LAC01
        *1 Front Drive Clutch Sleeve
        *2 Transfer Synchromesh Shifting Key Spring
        *3 No. 1 Synchromesh Shifting Key
        *a CORRECT
        *b INCORRECT
        B0068HS Rear Side

        Install the front drive clutch sleeve.

        Note

        Install the front drive clutch sleeve in the correct direction.

      2. Install the 2 transfer synchromesh shifting key springs and 3 No. 1 synchromesh shifting keys.

        Note


        • Install the shifting key springs so that their openings do not overlap as shown in the illustration.

        • Install the No. 1 synchromesh shifting keys so that they are securely attached to the 2 transfer synchromesh shifting key springs.

        • Install the No. 1 synchromesh shifting keys so that they do not rest on the ends of the transfer synchromesh shifting key springs as shown in the illustration.

        • Make sure that the transfer synchromesh shifting key springs are firmly connected to the No. 1 synchromesh shifting key.

        • Make sure that the front drive clutch sleeve moves smoothly.

    2. B0069CGC01
      B0068HS Rear Side

      w/o A.D.D.:

      Install the front drive clutch sleeve.

      Note

      Install the front drive clutch sleeve in the correct direction.

  3. INSTALL TRANSFER SYNCHRONIZER RING SET (w/ A.D.D.)

    Note

    Be careful not to drop the front drive clutch sleeve and No. 1 synchromesh shifting key.


    1. Apply transfer oil to the transfer synchronizer ring set.

    2. B0068H6

      Install the transfer synchronizer ring set.

      Note

      Align the key groove of the transfer synchronizer ring set with the No. 1 synchromesh shifting key, and then install the transfer synchronizer ring set.

  4. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

    Note


    • w/ A.D.D.:

      Be careful not to drop the front drive clutch sleeve and No. 1 synchromesh shifting key.

    • w/o A.D.D.:

      Be careful not to drop the front drive clutch sleeve.


    1. Apply transfer oil to the rolling and thrusting surfaces of the needle roller bearing, and the fitting surfaces of the transfer drive sprocket sub-assembly and front drive clutch sleeve.

    2. B00694WC01
      *1 Transfer Drive Sprocket Sub-assembly
      *2 Needle Roller Bearing
      *3 No. 1 Transfer Output Shaft Spacer

      Install the transfer drive sprocket sub-assembly.

    3. Install the needle roller bearing.

    4. Install the No. 1 transfer output shaft spacer.

    5. B0068DFC01
      B0068HS Rear Side

      Apply transfer oil to a new rear transfer output shaft radial ball bearing and the press-fit portion of the rear transfer output shaft.

    6. Using SST and a press, install the rear transfer output shaft radial ball bearing.

      SST
      09316-60011   ( 09316-00011, 09316-00051 )

      Note


      • Install the rear transfer output shaft radial ball bearing with the installation groove of the transfer output shaft snap ring facing the rear side as shown in the illustration.

      • Make sure the rear transfer output shaft radial ball bearing contacts the edge of the No. 1 transfer output shaft spacer, but do not press it in more than necessary.

      • Make sure that the transfer drive sprocket sub-assembly moves smoothly.

    7. Measure the transfer drive sprocket sub-assembly thrust clearance.

      Click here

  5. INSTALL TRANSFER CLUTCH HUB

    Note


    • w/ A.D.D.:

      Be careful not to drop the front drive clutch sleeve and No. 1 synchromesh shifting key.

    • w/o A.D.D.:

      Be careful not to drop the front drive clutch sleeve.


    1. Apply transfer oil to the transfer clutch hub and the press-fit portion of the rear transfer output shaft.

    2. B0069DDC01
      B0068HS Rear Side

      Using SST and a press, install the transfer clutch hub.

      SST
      09527-10011

      Note


      • Install the transfer clutch hub in the correct direction.

      • Make sure the transfer clutch hub contacts the edge of the rear transfer output shaft, but do not press it in more than necessary.

    3. B00697C

      Select a transfer clutch hub shaft snap ring from the table below so that the clearance between the transfer clutch hub and transfer clutch hub shaft snap ring is 0.15 mm (0.00590 in.) or less.

      Snap Ring Thickness
      Part No. Specified Condition
      90520-39013 2.00 to 2.05 mm (0.0788 to 0.0807 in.)
      90520-T0200
      90520-39014 2.05 to 2.10 mm (0.0808 to 0.0826 in.)
      90520-T0201
      90520-39004 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      90520-T0191
      90520-39005 2.15 to 2.20 mm (0.0847 to 0.0866 in.)
      90520-T0192
      90520-39006 2.20 to 2.25 mm (0.0867 to 0.0885 in.)
      90520-T0193
      90520-39007 2.25 to 2.30 mm (0.0886 to 0.0905 in.)
      90520-T0194
      90520-39008 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      90520-T0195
      90520-39009 2.35 to 2.40 mm (0.0926 to 0.0944 in.)
      90520-T0196
      90520-39010 2.40 to 2.45 mm (0.0945 to 0.0964 in.)
      90520-T0197
      90520-39011 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      90520-T0198
      90520-39012 2.50 to 2.55 mm (0.0985 to 0.1003 in.)
      90520-T0199
    4. Using a snap ring expander, install a new transfer clutch hub shaft snap ring.

    5. Install the transfer high and low clutch sleeve.

      Note

      Make sure that the transfer high and low clutch sleeve moves smoothly.

  6. INSTALL TRANSFER DRIVEN SPROCKET BEARING


    1. Apply transfer oil to 2 new transfer driven sprocket bearings and the press-fit portion of the transfer driven sprocket.

    2. B00697NN01

      for Rear Side:

      Using SST and a press, install the transfer driven sprocket bearing.

      SST
      09316-60011   ( 09316-00031 )

      Note


      • Make sure the transfer driven sprocket bearing contacts the edge of the transfer driven sprocket, but do not press it in more than necessary.

      • Make sure that the transfer driven sprocket bearing moves smoothly.

    3. B0068G7N01

      for Front Side:

      Using SST and a press, install the transfer driven sprocket bearing.

      SST
      09950-60010   ( 09951-00290 )
      09950-70010   ( 09951-07100 )
      09316-60011   ( 09316-00031 )
      09527-10011

      Note


      • Make sure the transfer driven sprocket bearing contacts the edge of the transfer driven sprocket, but do not press it in more than necessary.

      • Make sure that the transfer driven sprocket bearing moves smoothly.

  7. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY


    1. Apply transfer oil to the O-ring of the transfer shift actuator assembly.

    2. B006939

      Install the transfer shift actuator assembly with the 3 bolts.

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

      Note

      Do not damage the O-ring.

    3. B0068U5

      Using a screwdriver and hammer, install the transfer gear shift fork shaft snap ring.

      Tech Tips

      Install only the transfer gear shift fork shaft snap ring on the rear side of the transfer shift actuator shaft.

  8. INSTALL REAR TRANSFER OUTPUT SHAFT, TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVEN SPROCKET

    Note


    • w/ A.D.D.:

      Be careful not to drop the front drive clutch sleeve and No. 1 synchromesh shifting key.

    • w/o A.D.D.:

      Be careful not to drop the front drive clutch sleeve.

    • When using a vise, place aluminum plates between the part and vise.

    • When using a vise, do not over tighten it.


    1. B0069E3

      Install the rear transfer output shaft, transfer driven sprocket and transfer front drive chain with the No. 1 transfer gear shift fork and No. 2 transfer gear shift fork.

      Tech Tips

      When installation under normal temperatures is difficult, heat the rear transfer case to approximately 50 to 80°C (122 to 176°F), and then install it.

      CAUTION:

      Be careful not to burn yourself when the rear transfer case temperature is high.

    2. B0068ND

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

      Note

      After installation, if there is any clearance along the inside diameter of the transfer output shaft snap ring, replace it with a new one.

    3. B00696A

      Using a screwdriver and hammer, install the transfer gear shift fork shaft snap ring.

  9. INSTALL TRANSFER FRONT DRIVE SHIFT FORK SHAFT


    1. B0069BW

      Using a magnet hand, install the 2 shift interlock pin or rollers.

    2. B0069BOC01
      *1 Transfer Front Drive Shift Fork Shaft
      *2 No. 1 Transfer Gear Shift Fork
      *3 No. 2 Transfer Gear shift fork

      To install the transfer front drive shift fork shaft, shift the No. 1 transfer gear shift fork and No. 2 transfer gear shift fork to the positions shown in the illustration.

    3. Install the transfer front drive shift fork shaft.

    4. B0068NO

      Install the transfer shift shaft stopper with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    5. B0069CW

      Using a screwdriver and hammer, install the 2 transfer gear shift fork shaft snap rings.

    6. B0069C1C01
      *1 Shift Detent Ball Spring Plug
      *2 Shift Detent Ball Compression Spring
      *3 Shift Detent Ball

      Clean the 2 shift detent ball spring plug holes.

    7. Install the 2 shift detent balls and 2 shift detent ball compression springs.

    8. Using a 6 mm hexagon wrench, install 2 new shift detent ball spring plugs.

      Torque:
      18.6 N*m  { 190 kgf*cm, 14 ft.*lbf }
  10. INSTALL TRANSFER LOW PLANETARY GEAR BEARING


    1. Apply transfer oil to a new transfer low planetary gear bearing.

    2. B0068ZSN01

      Using SST and a press, install the transfer low planetary gear bearing as shown in the illustration.

      SST
      09950-60010   ( 09951-00470, 09951-00570, 09952-06010 )
      09950-70010   ( 09951-07150 )
      Drive in depth (A)
      7.7 to 8.3 mm (0.3032 to 0.3267 in.)
  11. INSTALL TRANSFER INPUT SHAFT BEARING


    1. B006962C01
      B0068HS Front Side

      Using SST and a press, install a new transfer input shaft bearing.

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

      Note


      • Install the transfer input shaft bearing with the installation groove of the transfer low planetary gear bearing shaft snap ring facing the front side as shown in the illustration.

      • Make sure the transfer input shaft bearing contacts the edge of the transfer low planetary ring gear, but do not press it in more than necessary.

    2. B006918

      Select a transfer input bearing shaft snap ring from the table below so that the clearance between the transfer input shaft bearing and transfer input bearing shaft snap ring is 0.1 mm (0.00393 in.) or less.

      Snap Ring Thickness
      Part No. Mark Specified Condition
      90520-72001 1 1.45 to 1.50 mm (0.0571 to 0.0590 in.)
      90520-T0136
      90520-72002 2 1.50 to 1.55 mm (0.0591 to 0.0610 in.)
      90520-T0137
      90520-72003 3 1.55 to 1.60 mm (0.0611 to 0.0629 in.)
      90520-T0138
      90520-72004 4 1.60 to 1.65 mm (0.0630 to 0.0649 in.)
      90520-T0139
      90520-72005 5 1.65 to 1.70 mm (0.0650 to 0.0669 in.)
      90520-T0140
    3. Using a snap ring expander, install a new transfer input bearing shaft snap ring.

  12. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING


    1. Apply transfer oil to the 2 No. 1 transfer input shaft seal rings.

    2. B006904

      Install the 2 No. 1 transfer input shaft seal rings.

      Note

      When installing the No. 1 transfer input shaft seal ring, do not expand the inside diameter to 65.0 mm (2.55 in.) or more.

  13. INSTALL TRANSFER INPUT SHAFT


    1. Apply transfer oil to the transfer low planetary gear bearing.

    2. B0068V5C01
      *1 Transfer Input Shaft
      *2 Transfer Low Planetary Gear Bearing
      *3 No. 1 Transfer Thrust Bearing Race

      Install the transfer low planetary gear bearing, No. 1 transfer thrust bearing race and transfer input shaft.

      Note

      When selecting a transfer low planetary gear bearing and No. 1 transfer thrust bearing race, select and install parts from the same manufacturer.

    3. B006963C01
      *1 Transfer Input Gear Stopper
      *2 Transfer Input Gear Stopper Ball
      *3 Manual Transfer Planetary Carrier Washer

      Apply transfer oil to the manual transfer planetary carrier washer.

    4. Install the manual transfer planetary carrier washer.

    5. Install the transfer input gear stopper and transfer input gear stopper ball.

    6. B0069ET

      Select a transfer input bearing shaft snap ring from the table below so that the thrust clearance of the transfer input gear stopper shaft snap ring is 0.05 to 0.15 mm (0.00197 to 0.00590 in.).

      Snap Ring Thickness
      Part No. Specified Condition
      90520-44003 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      90520-T0202
      90520-44004 2.15 to 2.20 mm (0.0847 to 0.0866 in.)
      90520-T0203
      90520-44005 2.20 to 2.25 mm (0.0867 to 0.0885 in.)
      90520-T0204
      90520-44006 2.25 to 2.30 mm (0.0886 to 0.0905 in.)
      90520-T0205
      90520-44007 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      90520-T0206
      90520-44008 2.35 to 2.40 mm (0.0926 to 0.0944 in.)
      90520-T0207
      90520-44009 2.40 to 2.45 mm (0.0945 to 0.0964 in.)
      90520-T0208
      90520-44010 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      90520-T0209
      90520-44011 2.50 to 2.55 mm (0.0985 to 0.100 in.)
      90520-T0210
      90520-44012 2.55 to 2.60 mm (0.101 to 0.102 in.)
      90520-T0211
      90520-44013 2.60 to 2.65 mm (0.103 to 0.104 in.)
      90520-T0212
      90520-44014 2.65 to 2.70 mm (0.105 to 0.106 in.)
      90520-T0213
      90520-44015 2.70 to 2.75 mm (0.107 to 0.108 in.)
      90520-T0214
      90520-44016 2.75 to 2.80 mm (0.109 to 0.110 in.)
      90520-T0215
      90520-44017 2.80 to 2.85 mm (0.111 to 0.112 in.)
      90520-T0216
      90520-44018 2.85 to 2.90 mm (0.113 to 0.114 in.)
      90520-T0217
      90520-44019 2.90 to 2.95 mm (0.115 to 0.116 in.)
      90520-T0218
      90520-44020 2.95 to 3.00 mm (0.117 to 0.118 in.)
      90520-T0219
      90520-44021 3.00 to 3.05 mm (0.119 to 0.120 in.)
      90520-T0220
    7. Using a snap ring expander, install a new transfer input gear stopper shaft snap ring.

      Note

      After installation, if there is any clearance along the inside diameter of the transfer input gear stopper shaft snap ring, replace it with a new one.

  14. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE


    1. Apply transfer oil to the transfer output shaft front needle roller bearing.

    2. B0069EU

      Install the transfer output shaft front needle roller bearing.

    3. B0068DQ

      Install the transfer low planetary gear spline piece.

    4. B00691PC01
      *a Protective Tape

      Using a screwdriver, install the transfer low planetary gear shaft snap ring.

      Note

      The transfer low planetary gear shaft snap ring should be installed completely.

      Tech Tips

      Tape the screwdriver tip before use.

  15. INSTALL TRANSFER LOW PLANETARY RING GEAR


    1. B0068BGC01
      *a Protective Tape
      B0068HS Front Side

      Install the transfer low planetary ring gear.

      Note

      Install the transfer low planetary ring gear in the correct direction.

    2. Using a screwdriver, install the transfer low planetary ring gear hole snap ring.

      Note

      The transfer low planetary gear shaft snap ring should be installed completely.

      Tech Tips

      Tape the screwdriver tip before use.

  16. INSTALL TRANSFER CASE PLUG


    1. Clean the transfer case plug hole.

    2. B0068SFC01
      *1 Transfer Case Plug
      *2 Transfer Case Compression Spring
      *3 Pin

      Install the pin and transfer case compression spring.

    3. Install a new transfer case plug.

      Torque:
      18.6 N*m  { 190 kgf*cm, 14 ft.*lbf }
  17. INSTALL TRANSFER LOW PLANETARY GEAR ASSEMBLY


    1. B0068QM

      Install the transfer low planetary gear assembly.

      Tech Tips

      When installation under normal temperatures is difficult, heat the front transfer case to approximately 50 to 80°C (122 to 176°F), and then install it.

      CAUTION:

      Be careful not to burn yourself when the front transfer case temperature is high.

    2. B00695L

      Using a snap ring expander, install the transfer low planetary gear bearing shaft snap ring.

      Note

      After installation, if there is any clearance along the inside diameter of the transfer low planetary gear bearing shaft snap ring, replace it with a new one.

  18. INSTALL TRANSFER FRONT BEARING TYPE T OIL SEAL


    1. for AC60F, R151F:

      Coat the lip of a new transfer front bearing type T oil seal with MP grease.

    2. for RC60F / RC61F:

      Coat the lip of 2 new transfer front bearing type T oil seals with MP grease.

    3. B0068N1N01

      for AC60F, R151F:

      Using SST and a hammer, install the transfer front bearing type T oil seal as shown in the illustration.

      SST
      09950-60010   ( 09951-00410, 09951-00570, 09952-06010 )
      09950-70010   ( 09951-07100 )
      Drive in depth (A)
      43.0 to 44.0 mm (1.70 to 1.73 in.)

      Note

      Be careful not to damage the transfer front bearing type T oil seal.

    4. for RC60F / RC61F:

      Using SST and a hammer, install the 2 transfer front bearing type T oil seals as shown in the illustration.

      SST
      09950-60010   ( 09951-00410, 09951-00570, 09952-06010 )
      09950-70010   ( 09951-07100 )
      B0068P2N01
      Drive in depth
      Drive in depth (A) 43.0 to 44.0 mm (1.70 to 1.73 in.)
      Drive in depth (B) 53.0 to 54.0 mm (2.09 to 2.12 in.)

      Note


      • Install the transfer front bearing type T oil seal in the correct direction.

      • Be careful not to damage the transfer front bearing type T oil seal.

  19. INSTALL TRANSFER FRONT BEARING RETAINER SUB-ASSEMBLY


    1. Clean the 5 bolt holes.

    2. B0068M8N01

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

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Seal width (A)
      1.2 mm (0.0472 in.)

      Note

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

    3. Apply adhesive to 2 or 3 threads on the end of the 5 new bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    4. B0068UW

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

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

      Note


      • Tighten the bolts of the transfer front bearing retainer sub-assembly within 10 minutes of applying the seal packing.

        The seal packing will dry very quickly.

      • Be careful not to damage the transfer front bearing type T oil seal.

    5. for RC60F / RC61F:


      1. Apply manual transmission oil to a new O-ring.

      2. Install the O-ring.

        Note


        • Do not scratch or twist the O-ring.

        • The O-ring should be installed completely.

  20. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY


    1. B0068UK

      Apply transfer oil to the transfer oil pump gear.

    2. Install the transfer oil pump gear.

    3. B00692Z

      Apply transfer oil to a new transfer oil pump body O-ring.

    4. Install the transfer oil pump body O-ring.

      Note


      • Do not scratch or twist the transfer oil pump body O-ring.

      • The transfer oil pump body O-ring should be installed completely.

    5. B0068P6

      Install the transfer oil pump body sub-assembly with the 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
  21. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY


    1. B006909

      Install the transfer case magnet.

    2. Install the transfer oil separator sub-assembly with the 3 bolts.

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

      Note

      Be careful not to damage the transfer oil pump body O-ring.

  22. INSTALL REAR TRANSFER CASE


    1. Apply transfer oil to the transfer output shaft front needle roller bearing, the inside diameter of the internal bush portion of the transfer input shaft and the fitting surfaces of the high and low clutch sleeve and transfer low planetary gear assembly.

    2. B0068T9N01

      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
      Seal width (A)
      1.2 mm (0.0472 in.)

      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 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.

    3. B006935C01
      *1 Bracket

      Install the rear transfer case and 4 brackets 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.

  23. INSTALL TRANSFER OUTPUT SHAFT WASHER


    1. B0069DCC01
      *1 Transfer Output Shaft Washer
      *2 No. 2 Transfer Output Shaft Spacer

      Install the No. 2 transfer output shaft spacer.

    2. Install the 2 transfer output shaft washers.

  24. INSTALL TRANSFER EXTENSION HOUSING


    1. Clean the 5 bolt holes.

    2. B0068PPN01

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

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Seal width (A)
      1.2 mm (0.0472 in.)

      Note

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

    3. Apply adhesive to 2 or 3 threads on the end of the 5 new bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    4. B0069FY

      Install the transfer extension housing with the 5 bolts.

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

      Note

      Tighten the bolts of the transfer extension housing within 10 minutes of applying the seal packing.

      The seal packing will dry very quickly.

  25. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

    Click here

  26. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Rear Side)


    1. B00695YN01

      for Type A:

      Using SST and hammer, install a new transfer output shaft companion flange oil seal.

      SST
      09950-60011   ( 09951-00310, 09951-00440 )
      09950-70010   ( 09951-07100 )
      Drive in depth (A)
      36.7 to 37.7 mm (1.44 to 1.48 in.)

      Note


      • Install the transfer output shaft companion flange oil seal in the correct direction.

      • Be careful not to damage the transfer output shaft companion flange oil seal.

    2. for Type B:


      1. Apply transfer oil to a new transfer output shaft O-ring.

      2. Install the transfer output shaft O-ring.

    3. Apply transfer oil to the fitting portions of the output shaft companion flange sub-assembly and rear transfer output shaft.

    4. B0068BBC01
      *a Turn
      *b Hold

      Using SST to hold the output shaft companion flange sub-assembly, install a new transfer output shaft companion flange nut.

      SST
      09330-00021
      Torque:
      127.4 N*m  { 1299 kgf*cm, 94 ft.*lbf }

      Note


      • Do not scratch or twist the transfer output shaft O-ring.

      • The transfer output shaft O-ring should be installed completely.

    5. B00697KC01
      *1 Transfer Output Shaft Companion Flange Nut
      *2 Rear Transfer Output Shaft
      *a Correct
      *b Incorrect

      Using a chisel and hammer, stake the transfer output shaft companion flange nut as shown in the illustration.

  27. INSTALL TRANSFER CASE OIL SEAL

    Click here

  28. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Front Side)


    1. B0068ZTN01

      Using SST and hammer, install a new transfer output shaft companion flange oil seal.

      SST
      09950-60010   ( 09951-00220, 09951-00310, 09952-06010 )
      09950-70010   ( 09951-07100 )
      Drive in depth (A)
      38.0 to 39.0 mm (1.50 to 1.53 in.)

      Note


      • Install the transfer output shaft companion flange oil seal in the correct direction.

      • Be careful not to damage the transfer output shaft companion flange oil seal.

    2. Apply transfer oil to the fitting portions of the output shaft companion flange sub-assembly and transfer driven sprocket.

    3. B0068PDC01
      *a Turn
      *b Hold

      Using SST to hold the output shaft companion flange sub-assembly, install a new transfer output shaft companion flange nut.

      SST
      09330-00021
      Torque:
      118 N*m  { 1203 kgf*cm, 87 ft.*lbf }
    4. B00697KC01
      *1 Transfer Output Shaft Companion Flange Nut
      *2 Rear Transfer Output Shaft
      *a Correct
      *b Incorrect

      Using a chisel and hammer, stake the transfer output shaft companion flange nut as shown in the illustration.

  29. INSTALL NO. 1 TRANSFER CASE PLUG


    1. B0068K1C01
      *1 No. 1 Transfer Case Plug (Filler Plug)
      *2 No. 1 Transfer Case Gasket
      *3 Transfer Drain Plug
      *4 Transfer Drain Plug Gasket

      Install a new No. 1 transfer case gasket to the No. 1 transfer case plug (filler plug), and then install the No. 1 transfer case plug (filler plug).

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    2. Install a new transfer drain plug gasket to the transfer drain plug, and then install the transfer drain plug.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
  30. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY


    1. B0068VA

      Install the breather oil deflector.

    2. B0068LJ

      Install the transfer case cover sub-assembly with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
  31. INSTALL ACTUATOR BREATHER HOSE


    1. B0068G2C01
      *a 0 to 3.0 mm

      Install the 2 clamps and actuator breather hose as shown in the illustration.

      Note


      • Install the actuator breather hose so that it passes between the rear transfer case and transfer shift actuator assembly.

      • Fully install the actuator breather hose to the base of the transfer shift actuator assembly.

      • Install the actuator breather hose so that the net protector in area A extends 0 to 3.0 mm (0 to 0.118 in.) from the clamp.