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. A01EQT3

      Install a new needle roller bearing.

    2. A01ERR2E01

      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. A01ENH6

      Install the bearing to the output shaft.

  3. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. A01EPD5

      Install the drive sprocket to the output shaft.

  4. INSTALL TRANSFER OUTPUT SHAFT SPACER


    1. A01ER48E01

      Install the straight pin to the output shaft.

    2. A01EQYN

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

    3. A01EN7O

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

  5. INSPECT TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. A01ESO8

      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. A01EROJE01

      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. A01ES1SE01

      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. A01ERFN

      Install the center differential case to the output shaft.

  7. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A01ESLXE01

      Install the straight pin to the output shaft.

    2. A01ENZ3

      Install a new seal ring to the output shaft spacer.

    3. A01ERQA

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

    4. A01EOVX

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

  8. INSTALL TRANSFER OUTPUT SHAFT WASHER


    1. A01ESF8

      Install the 2 output shaft washers to the output shaft.

  9. INSTALL TRANSFER INPUT SHAFT PLUG


    1. A01EMUKE01

      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. A01ER2YE01

      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. A01EPUHE01

      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. A01EOZ1E01

      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. A01EOQQE01

      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. A01EN3C

      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

    A01EPMBE01

    1. Apply transfer oil to a new seal ring.

    2. Install the seal ring to the input shaft.

  13. INSTALL TRANSFER DRIVEN SPROCKET BEARING


    1. A01EPI4

      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. A01ENSK

      Using a screwdriver, install the snap ring.

  14. INSTALL TRANSFER LOW PLANETARY RING GEAR


    1. A01EOB5

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

    2. A01ER18E01

      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. A01ESIQ

      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. A01ENGM

      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. A01EPBM

      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. A01EOJ9

      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. A01EQ0O

      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. A01EQH8E01

      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. A01ENDQ

      Using a screwdriver, install the snap ring.

  19. INSTALL FRONT DRIVE CLUTCH SLEEVE

    A01ESI2E01

    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. A01ERIJ

      Install the snap ring to the rear transfer case.

    2. A01EQ40E01

      Install the output shaft, drive chain and driven sprocket.

      Note

      Do not drop the output shaft washers.

    3. A01EQBX

      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. A01ES6RE02

      Install a new O-ring to the shift actuator.

    2. A01ENOWE01

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

    3. A01ENQQ

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

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    4. A01ER9P

      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. A01EPPIE01

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

    2. A01EPDS

      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. A01EOQP

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

  23. INSTALL FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING


    1. A01EN0YE01

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

  24. INSTALL REAR TRANSFER CASE ASSEMBLY


    1. A01EQTGE01

      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 material on the rear transfer case contact surface, 2) clean off any remaining old FIPG material from the rear transfer case contact surface, and 3) reapply seal packing to the rear transfer case.

    2. A01EP44

      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.

  25. 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. A01EP2C

      Using a 6 mm hexagon wrench, install the plug.

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

  26. INSTALL NO. 1 TRANSFER CASE PLUG


    1. A01EP8O

      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 }

  27. INSTALL TRANSFER CASE REAR OIL SEAL


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

    2. A01EMV9E01

      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 )

  28. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Install the companion flange onto the output shaft.

    2. A01EMVWE01

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

      SST
      09330-00021
      Torque:
      127 N*m  { 1299 kgf*cm, 94 ft.*lbf }
    3. A01ERE9E01

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

  29. INSTALL TRANSFER CASE FRONT OIL SEAL


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

    2. A01ENNQE02

      Using SST and a hammer, tap in a new oil seal until its surface is 1 to 1.5 mm (0.0394 to 0.0590 in.) from the case upper surface.

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

  30. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Install the companion flange onto the drive sprocket.

    2. A01ERUYE01

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

      SST
      09330-00021
      Torque:
      127 N*m  { 1299 kgf*cm, 94 ft.*lbf }
    3. A01ERE9E01

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

  31. INSTALL TRANSFER OIL PUMP PLATE OIL SEAL


    1. A01ENCIE01

      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.

  32. INSTALL TRANSFER CASE PLUG


    1. A01ES3Y

      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 }

  33. INSTALL TRANSFER CASE STRAIGHT PIN


    1. A01EQSRE01

      Install the 2 straight pins to the input shaft.

  34. INSTALL TRANSFER OIL PUMP PLATE


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

    2. A01EP33E01

      Install the drive rotor to the input shaft.

    3. A01EOB3

      Install the transfer oil seal ring to the input shaft.

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

    5. A01ENOG

      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 }

  35. INSTALL PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY


    1. A01ENR6

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

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