TRANSFER ASSEMBLY REASSEMBLY


  1. INSTALL TRANSFER LOW PLANETARY RING GEAR

    A01J510E01

    1. Install the ring gear to the front case.

      Note

      Make sure to install the ring gear in the correct direction.

    2. A01J640

      Using a screwdriver, install the snap ring.

      Note

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

  2. INSTALL TRANSFER CASE STRAIGHT PIN

    A01J6FDE01

  3. INSTALL COMPRESSION SPRING

  4. INSTALL TRANSFER CASE PLUG


    1. Apply adhesive to the threads of the plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the case plug.

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

  5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER

    A01J5ZAE02

  6. INSTALL TRANSFER DRIVE SPROCKET BEARING

  7. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

  8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER

  9. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING

    A01J6P2E01

    1. Apply gear oil to the connecting areas of the output shaft and bearing.

    2. Using SST and a press, press in a new bearing with the outer race snap ring groove toward the rear.

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

  10. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER

    A01J66XE01

  11. INSTALL FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING

  12. INSTALL TRANSFER CLUTCH HUB

  13. INSTALL CENTER DIFFERENTIAL CASE

    A01J4UJE01

  14. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL

  15. INSTALL NO. 2 TRANSFER OUTPUT SHAFT SPACER

  16. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING


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

      Note

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

  17. INSPECT TRANSFER DRIVE SPROCKET RADIAL CLEARANCE

    A01J5YV

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

      Standard clearance
      0.01 to 0.06 mm (0.0004 to 0.0024 in.)
      Maximum clearance
      0.06 mm (0.0024 in.)

      If the clearance is greater than the maximum, replace the drive sprocket, output shaft or needle roller bearing.

  18. INSPECT TRANSFER DRIVE SPROCKET THRUST CLEARANCE

    A01J5SC

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

      Standard clearance
      0.15 to 0.24 mm (0.0059 to 0.0094 in.)
      Maximum clearance
      0.24 mm (0.0094 in.)

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

  19. INSTALL TRANSFER LOW PLANETARY GEAR BEARING

    A01J4ROE01

    1. Using SST and a press, press in a new bearing.

      SST
      09950-60010   ( 09951-00570 )
      09950-70010   ( 09951-07100 )
      Standard depth
      7.7 to 8.3 mm (0.303 to 0.327 in.)

  20. INSTALL TRANSFER INPUT SHAFT BEARING

    A01J7J2E01

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

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

  21. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE

    A01J7A0

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

      Note


      • Be careful not to damage the spline piece.

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

  22. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING

    A01J6HX

    1. Select a new snap ring that allows 0.1 mm (0.0039 in.) or less of axial free play.

      Standard snap ring thickness
      Mark Thickness
      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.)

      Note

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

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

  23. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING

    A01J6R4

    1. Apply gear oil to the 2 seal rings.

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

      Tech Tips

      Engage the seal rings securely to eliminate clearance as shown in the illustration.

  24. INSTALL TRANSFER LOW PLANETARY GEAR BEARING

    A01J4L9E01

    1. Install the bearing to the low planetary gear.

      Note

      Make sure to install the bearing in the correct direction.

  25. INSTALL NO. 1 TRANSFER THRUST BEARING RACE

  26. INSTALL TRANSFER INPUT SHAFT


    1. Apply gear oil to the contact surface of the input shaft and low planetary gear.

    2. Install the input shaft to the low planetary gear.

  27. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER

    A01J3GZE01

    1. Apply gear oil to the washer.

    2. Install the washer to the low planetary gear.

  28. INSTALL TRANSFER INPUT GEAR STOPPER BALL

  29. INSTALL TRANSFER INPUT GEAR STOPPER

  30. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING

    A01J55M

    1. Select a new snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) of axial free play.

      Standard snap ring thickness
      Thickness
      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 0.1004 in.)
      2.55 to 2.60 mm (0.1004 to 0.1024 in.)
      2.60 to 2.65 mm (0.1024 to 0.1043 in.)
      2.65 to 2.70 mm (0.1043 to 0.1063 in.)
      2.70 to 2.75 mm (0.1063 to 0.1083 in.)
      2.75 to 2.80 mm (0.1083 to 0.1102 in.)
      2.80 to 2.85 mm (0.1102 to 0.1122 in.)
      2.85 to 2.90 mm (0.1122 to 0.1142 in.)
      2.90 to 2.95 mm (0.1142 to 0.1161 in.)
      2.95 to 3.00 mm (0.1161 to 0.1181 in.)
      3.00 to 3.05 mm (0.1181 to 0.1201 in.)

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

      Note

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

  31. INSTALL TRANSFER CASE OIL SEAL

    A01J4L5E01

    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 1).

      SST
      09316-60011   ( 09316-00011 )

      Note

      Be careful not to damage the front case.

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

    3. A01J3KYE01

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 2).

      SST
      09304-12012
      Standard depth
      -0.5 to 0.5 mm (-0.020 to 0.020 in.)

      Note

      Be careful not to damage the front case.

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

  32. INSTALL TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT

    A01J47W

    1. Install the low planetary gear with input shaft.

      Tech Tips

      If necessary, heat the front case to about 50 to 80°C (122 to 176°F).

    2. A01J4KW

      Using a snap ring expander, install the snap ring.

      Note

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

  33. INSTALL TRANSFER OIL PUMP GEAR

    A01J6D3

    1. Apply gear oil to the sliding surface of the gear.

    2. Install the gear with the nut.

  34. INSTALL TRANSFER OIL PUMP BODY O-RING

    A01J5C4

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

  35. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY

    A01J79Q

    1. Install the pump body with the 3 bolts.

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

  36. INSTALL TRANSFER CASE MAGNET

    A01J6HL

  37. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY


    1. Install the oil separator with the 3 bolts.

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

  38. INSTALL NO. 1 TRANSFER CASE PLUG (for Filler)


    1. Install a new gasket and the filler plug.

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

  39. INSTALL NO. 1 TRANSFER CASE PLUG (for Drain)


    1. Install a new gasket and the filler plug.

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

  40. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING

    A01J5JVE01

    1. Apply gear oil to the contact surface of the bearing and driven sprocket.

    2. Using SST and a press, press in a new bearing.

      SST
      09316-60011   ( 09316-00031 )

      Note

      After press-fitting the bearing to the driven sprocket, check that the bearing moves smoothly.

  41. INSTALL TRANSFER DRIVEN SPROCKET BEARING

    A01J4C3

    1. Apply gear oil to the contact surfaces of the bearing and driven sprocket.

    2. Using a press, press in a new bearing.

      Note

      After press-fitting the bearing to the driven sprocket, check that the bearing moves smoothly.

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

    A01J3P4

    1. Install the output shaft and driven sprocket to the front drive chain.

    2. A01J5RH

      Mount the rear case in a vise.

      Note

      Place aluminum plates on the vise to prevent damage to the rear case.

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

      Tech Tips

      Check that the output shaft and driven sprocket turn smoothly. If necessary, heat the rear case to about 50 to 80°C (122 to 176°F).

    4. A01J461

      Using a snap ring expander, install the snap ring.

      Note

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

  43. INSTALL CENTER DIFFERENTIAL LOCK FORK WITH FRONT DRIVE CLUTCH SLEEVE

    A01J3MAE01

    1. Install the clutch sleeve.

      Note

      Make sure to install the clutch sleeve in the correct direction.

    2. Install the front drive shift shaft, center differential lock fork, shift shaft stopper, 2 springs and 3 stoppers.

    3. Install the ball and spring to the hole.

    4. Apply adhesive to the threads of the No. 2 plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    5. Install the No. 2 plug to the hole.

      Torque:
      18.6 N*m  { 190 kgf*cm, 14 ft.*lbf }
    6. A01J5IJE01

      Using a pin punch and hammer, tap in the slotted pin.

      Note

      When installing the slotted pin, make sure the pin's groove (labeled A) is facing in the same direction as the shaft.

  44. INSTALL NO. 2 TRANSFER GEAR SHIFT FORK WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE

    A01J548E01

    1. Manual transmission:

      Install the synchronizer ring, 3 shifting keys and 2 springs.

      Note


      • Set the No. 1 springs so that their openings do not overlap, as shown in the illustration.

      • Make sure that the No. 1 springs are firmly connected to the shifting keys.

    2. Install the straight pin to the hole.

    3. A01J4JIE01

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

      Note

      Make sure to install the fork in the correct direction.

    4. Install the ball and spring to the hole.

    5. Apply adhesive to the threads of the No. 1 plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Install the No. 1 plug to the hole.

    7. A01J5IJE01

      Using a pin punch and hammer, install the slotted pin.

      Note

      When installing the slotted pin, make sure the pin's groove (labeled A) is facing in the same direction as the shaft.

  45. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING


    1. Apply gear oil to the bearing.

    2. Install the bearing to the low planetary gear.

  46. INSTALL REAR TRANSFER CASE

    A01J3PUE05

    1. Apply seal packing to the rear case as shown in the illustration.

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

      Note

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

    2. A01J611

      Install the clamps and rear case with the 12 bolts.

      Torque:
      28 N*m  { 285 kgf*cm, 21 ft.*lbf }

      Note

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

  47. INSTALL TRANSFER OUTPUT SHAFT WASHER


    1. Install the speedometer drive gear and 2 output washers.

  48. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

    A01J6OHE01

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

      SST
      09223-46011
      09631-32020

      Note

      Be careful not to damage the extension housing.

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

  49. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY

    A01J5L3E05

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

    2. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. 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 SPEEDOMETER DRIVEN GEAR SUB-ASSEMBLY


    1. A01J4C4

      Install a new O-ring to the speedometer sensor.

    2. A01J4CC

      Install the speedometer driven gear subassembly to the speedometer sensor with the clip.

  51. INSTALL SPEEDOMETER DRIVEN GEAR WITH VEHICLE SPEED SENSOR


    1. A01J5IL

      Install the speedometer driven gear assembly with vehicle speed sensor with the bolt.

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

    2. Connect the connector.

  52. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (for Front)

    A01J3O2E01

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

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

      Note

      Be careful not to damage the companion flange.

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

  53. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (for Rear)


    1. Using SST and a hammer, tap in a new oil seal (for rear) in the same way as the oil seal (for front).

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

      Note

      Be careful not to damage the companion flange.

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

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

    A01J60RE02

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

    2. Install the companion flange to the driven sprocket.

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

      SST
      09330-00021
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09955-04051, 09957-04010, 09958-04011 )
      Torque:
      118 N*m  { 1,203 kgf*cm, 87 ft.*lbf }
    4. A01J3WKE01

      Using a chisel and hammer, stake the lock nut to the driven sprocket.

      Note


      • Thoroughly stake the shaft to the lock nut's groove.

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

      • Do not apply excessive force to the shaft.

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


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

    2. Install the companion flange to the output shaft.

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

      SST
      09330-00021
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )
      Torque:
      118 N*m  { 1,203 kgf*cm, 87 ft.*lbf }

  56. INSTALL BREATHER OIL DEFLECTOR

  57. INSTALL TRANSFER CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY (for Transfer on Type)

    A01J301

    1. Install the retainer with the 4 bolts.

      Torque:
      18 N*m  { 183 kgf*cm, 13 ft.*lbf }

  58. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY (for Adapter on Type)

    A01J37S

    1. Install the case cover with the 4 bolts.

      Torque:
      18 N*m  { 183 kgf*cm, 13 ft.*lbf }

  59. INSTALL TRANSFER COVER TYPE T OIL SEAL

    A01J65TE01

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

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

      Note

      Be careful not to damage the bearing retainer.

  60. INSTALL TRANSFER BEARING RETAINER SUB-ASSEMBLY

    A01J3DHE05

    1. Apply seal packing to the bearing retainer as shown in the illustration.

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

      Note

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

    2. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the bearing retainer with the 5 bolts.

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

      Note

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

  61. INSTALL TRANSFER GEAR SHIFT HEAD

    A01J3AFE01

    1. Install the No. 1 and No. 2 gear shift heads to the front drive shift fork shaft and high and low shift fork shaft.

    2. A01J5IJE01

      Using a pin punch and hammer, tap in the 2 slotted pins to the No. 1 and No. 2 gear shift heads.

      Note

      When installing the slotted pins, make sure the pin's groove (labeled A) is facing in the same direction as the shaft.

  62. INSTALL TRANSFER INDICATOR SWITCH

    A01J3KVE01

    1. Install a new gasket and the indicator switch.

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

      Tech Tips

      Indicator switch:

      No. 1 Indicator switch (neutral position) for automatic transmission
      No. 2 Indicator switch (L4 position)
      No. 3 Indicator switch (differential lock)