TRANSFER ASSEMBLY REASSEMBLY

Tech Tips

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


  1. INSTALL REAR TRANSFER OUTPUT SHAFT


    1. A0155KW

      Install a new needle roller bearing.

    2. A015BQKE01

      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. A015BU1

      Install the bearing to the output shaft.

  3. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. A01573H

      Install the drive sprocket to the output shaft.

  4. INSTALL TRANSFER OUTPUT SHAFT SPACER


    1. A015CC8E01

      Install the straight pin to the output shaft.

    2. A015BY7

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

    3. A015571

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

  5. INSPECT TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. A015DPY

      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. A015DT8E01

      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. A015C7HE01

      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. A0159DEE01

      for Manual Transmission:

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

    4. A015DK5

      for Manual Transmission:

      Using a snap ring expander, install the snap ring.

    5. A015CNR

      Install the center differential case to the output shaft.

  7. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A015BR0E01

      Install the straight pin to the output shaft.

    2. A015CWM

      Install a new seal ring to the output shaft spacer.

    3. A015BKV

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

    4. A015COB

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

  8. INSTALL TRANSFER OUTPUT SHAFT WASHER


    1. A0159UJ

      Install the 2 output shaft washers to the output shaft.

  9. INSTALL TRANSFER INPUT SHAFT PLUG


    1. A015A7TE01

      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. A015BH8E01

      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. A015BAYE01

      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. A015AZBE01

      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. A015BVXE01

      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. A0157KD

      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

    A015A2ME01

    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. A0155GP

      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. A0156ZD

      Using a screwdriver, install the snap ring.

  14. INSTALL TRANSFER LOW PLANETARY RING GEAR


    1. A015C4U

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

    2. A0157NAE01

      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. A015AQV

      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. A015C2R

      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. A01579K

      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. A01570L

      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. A0156B6

      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. A015E6XE01

      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. A015AQS

      Using a screwdriver, install the snap ring.

  19. INSTALL FRONT DRIVE CLUTCH SLEEVE

    A0159XAE01

    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. A015ATC

      Install the snap ring to the rear transfer case.

    2. A0156MQE01

      Install the output shaft, drive chain and driven sprocket.

      Note

      Do not drop the output shaft washers.

    3. A015BYI

      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. A0156SFE02

      Install a new O-ring to the shift actuator.

    2. A015BO9E01

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

    3. A0158U8

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

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    4. A015DZ6

      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. A015AIQE01

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

    2. A0157CL

      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. A015CIZ

      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. A0157WVE01

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

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

    A01573Q

    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. A0158LPE01

      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. A015CJV

      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. A0157J2

      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. A0155U0

      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


    1. Apply transfer oil to the spline of the output shaft.

    2. A015DSDE01

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

      SST
      09649-17010
      09950-70010   ( 09951-07150 )

  29. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Install the companion flange onto the output shaft.

    2. A015A1KE01

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

      SST
      09330-00021
      Torque:
      127 N*m  { 1299 kgf*cm, 94 ft.*lbf }
    3. A01573YE01

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

  30. INSTALL TRANSFER CASE FRONT OIL SEAL


    1. Apply transfer oil to the spline of the driven sprocket.

    2. A015C8EE01

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

      SST
      09613-26010

      Note

      The front transfer case oil seal should be installed completely.

  31. INSTALL TRANSFER OUTPUT SHAFT DUST DEFLECTOR


    1. A0158STE01

      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. A015DLPE01

      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. A015D0JE01

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

      SST
      09330-00021
      Torque:
      127 N*m  { 1299 kgf*cm, 94 ft.*lbf }
    3. A01573YE01

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

  33. INSTALL TRANSFER OIL PUMP PLATE OIL SEAL


    1. A0156FNE01

      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. A0156O8

      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. A015DV9E01

      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. A015ALZE01

      Install the drive rotor to the input shaft.

    3. A015A6G

      Install the transfer oil seal ring to the input shaft.

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

    5. A015870

      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. A015688

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

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