TRANSFER ASSEMBLY REASSEMBLY


  1. INSTALL TRANSFER CONTROL SOLENOID ASSEMBLY


    1. A01FF8WE01
      Text in Illustration
      *1 Transfer Control Solenoid Assembly
      *2 Solenoid Lock Plate
      *a Cutout

      Install the transfer control solenoid assembly and solenoid lock plate to the transfer control valve body assembly with the bolt.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

      Tech Tips

      Install the solenoid lock plate into the cutout on the transfer control solenoid assembly.

  2. INSTALL TRANSFER DRIVE SPROCKET BEARING


    1. A01FFP7E02
      Text in Illustration
      *1 Transfer Drive Sprocket Bearing

      Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket sub-assembly.

      SST
      09316-20011
      09950-60010   ( 09951-00640 )
      09950-70010   ( 09951-07100 )
    2. A01FI0RE03
      Text in Illustration
      *1 Transfer Drive Sprocket Bearing
      *a Shield Facing Upward

      Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket sub-assembly.

      SST
      09316-60011   ( 09316-00011 )

      Note

      Install the transfer drive sprocket bearing with the shield facing upward.

  3. INSTALL TRANSFER DRIVEN SPROCKET BEARING


    1. A01FHGOE02
      Text in Illustration
      *1 Transfer Driven Sprocket Bearing

      Using SST and a press, install a new transfer driven sprocket bearing to the transfer front drive clutch sleeve sub-assembly.

      SST
      09316-20011
      09950-60010   ( 09951-00640 )
      09950-70010   ( 09951-07100 )
    2. A01FI8ME02
      Text in Illustration
      *1 Transfer Driven Sprocket Bearing

      Using SST and a press, install a new transfer driven sprocket bearing to the transfer front drive clutch sleeve sub-assembly.

      SST
      09316-60011   ( 09316-00011, 09316-00041 )

  4. INSTALL TRANSFER CENTER SUPPORT SEAL RING


    1. A01FIQF

      Coat the 2 transfer center support seal rings with ATF.

      ATF
      Toyota Genuine ATF WS

    2. Compress the 2 transfer center support seal rings as shown in the illustration and install them into the grooves on the transfer center support assembly.

      Note


      • Do not expand the ring ends excessively.

      • If any ring is damaged or deformed, replace it with a new one.

  5. INSTALL TRANSFER CENTER SUPPORT ASSEMBLY


    1. A01FGCS

      Install the transfer center support assembly to the transfer rear chain case assembly with the 5 bolts.

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

    2. Coat 2 new O-rings with ATF.

      ATF
      Toyota Genuine ATF WS

    3. Install the 2 O-rings to the screws.

    4. Install the 2 screws to the transfer rear chain case assembly.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }

  6. INSTALL TRANSFER DIRECT CLUTCH PISTON O-RING


    1. A01FIDXE03
      Text in Illustration
      *1 Transfer Direct Clutch Piston O-ring

      Coat 2 new transfer direct clutch piston O-rings with ATF.

      ATF
      Toyota Genuine ATF WS

    2. Install the 2 transfer direct clutch piston O-rings to the center differential clutch piston.

      O-ring size:
      Installation position

      Inner diameter

      mm (in.)

      Thickness

      mm (in.)
      Inner

      56.45 to 57.45

      (2.223 to 2.261)

      2.54 to 2.70

      (0.100 to 0.106)
      Outer

      116.20 to 117.80

      (4.575 to 4.637)

      3.0 to 3.2

      (0.119 to 0.125)

  7. INSTALL CENTER DIFFERENTIAL CLUTCH PISTON


    1. A01FIBP

      Install the center differential clutch piston to the transfer direct clutch drum sub-assembly.

      Note

      Do not damage the transfer direct clutch piston O-ring.

  8. INSTALL TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY


    1. A01FFVG

      Install the transfer direct clutch return spring assembly to the transfer direct clutch drum sub-assembly.

  9. INSTALL CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER


    1. A01FF3GE03
      Text in Illustration
      *a Rubber

      Coat the rubber on the center differential clutch pressure balancer with ATF.

      ATF
      Toyota Genuine ATF WS

    2. Install the center differential clutch pressure balancer to the transfer direct clutch drum sub-assembly.

    3. A01FGSIE03
      Text in Illustration
      *1 Transfer Direct Clutch Return Spring Snap Ring

      Place SST on the center differential clutch pressure balancer, and compress the transfer direct clutch return spring assembly with a press.

      SST
      09350-30020   ( 09350-07040 )

    4. Using SST, install the transfer direct clutch return spring snap ring.

      SST
      09350-30020   ( 09350-07040, 09350-07070 )

  10. INSTALL CENTER DIFFERENTIAL CLUTCH DISC SET


    1. A01FFZ8E02
      Text in Illustration
      *1 Center Differential Clutch Disc Flange (No. 1)
      *2 Center Differential Clutch Disc Set (Discs)
      *3 Center Differential Clutch Disc Set (Plates)
      *4 Center Differential Clutch Disc Flange (No. 2)

      Install the 2 center differential clutch disc flanges and center differential clutch disc set to the transfer direct clutch drum sub-assembly.

      Install in the following order
      *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 -*3 - *2 - *4

      Note

      Before assembling new discs, soak them in ATF for at least 15 minutes.

      ATF
      Toyota Genuine ATF WS
    2. A01FHCIE03
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip taped, install the transfer direct clutch flange snap ring to the transfer direct clutch drum sub-assembly.

    3. A01FJ0ZE03
      Text in Illustration
      *1 Transfer Direct Clutch Drum Sub-assembly
      *2 Transfer Center Support Assembly

      Install the transfer direct clutch drum sub-assembly to the transfer center support assembly.

    4. A01FESME03
      Text in Illustration
      *1 Center Differential Clutch Disc Flange (No. 1)
      *2 Center Differential Clutch Pressure Balancer
      *3 Center Differential Clutch Piston
      *a Oil Hole

      Set the dial indicator perpendicular to the center differential clutch disc flange (No. 1).

    5. Apply air (200 kPa, 2.0 kgf/cm2, 19 psi) at the oil hole as shown in the illustration. Measure the pack clearance.

      Standard Clearance
      0.40 to 0.80 mm (0.0158 to 0.0314 in.)

      Tech Tips


      • Check that the center differential clutch piston moves smoothly.

      • Perform the measurement at 2 or 3 points and take the average.

    6. A01FF24E04
      Text in Illustration
      *1 Center Differential Clutch Disc Flange (No. 1)

      If the clearance is not within the specified range, select another center differential clutch disc flange (No. 1).

      Flange Thickness:
      Mark Thickness mm (in.)
      90 2.95 to 3.05 (0.117 to 0.120)
      91 3.15 to 3.25 (0.125 to 0.127)
      92 3.35 to 3.45 (0.132 to 0.135)
    7. A01FJ0ZE03
      Text in Illustration
      *1 Transfer Direct Clutch Drum Sub-assembly
      *2 Transfer Center Support Assembly

      Remove the transfer direct clutch drum sub-assembly from the transfer center support assembly.

  11. INSTALL TRANSFER REAR OUTPUT SHAFT BEARING


    1. A01FH6P

      Attach the 2 guides to install the transfer rear output shaft bearing to the center differential carrier assembly.

  12. INSTALL TRANSFER REAR OUTPUT SHAFT ASSEMBLY AND CENTER DIFFERENTIAL CARRIER ASSEMBLY


    1. A01FG5DE03
      Text in Illustration
      *1 Transfer Rear Output Shaft Assembly
      *2 Center Differential Carrier Assembly
      *3 Transfer Direct Clutch Drum Sub-assembly

      Install the transfer rear output shaft assembly and center differential carrier assembly to the transfer direct clutch drum sub-assembly.

  13. INSTALL TRANSFER CHAIN CASE OIL SEAL


    1. A01FH43E02

      Using SST and a hammer, install a new transfer chain case oil seal.

      SST
      09316-60011   ( 09316-00011, 09316-00071 )
      Oil seal drive in depth
      5.6 to 6.2 mm (0.221 to 0.244 in.)

    2. Apply MP grease to the transfer chain case oil seal lip.

  14. INSTALL TRANSFER CHAIN CASE GOVERNOR APPLY GASKET


    1. A01FDLG

      Coat 2 new transfer chain case governor apply gaskets with ATF.

      ATF
      Toyota Genuine ATF WS

    2. Install the 2 transfer chain case governor apply gaskets to the transfer rear chain case assembly.

    3. A01FFBYE03
      Text in Illustration
      *A for Front Side
      *B for Rear Side
      *1 Transfer Chain Case Governor Apply Gasket
      *2 O-ring
      *3 Screw

      Coat a new O-ring and 2 new transfer chain case governor apply gaskets with ATF.

      ATF
      Toyota Genuine ATF WS

    4. Install the O-ring to the screw.

    5. Install the 2 transfer chain case governor apply gaskets and screw to the transfer front chain case.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }

  15. INSTALL TRANSFER BAFFLE VALVE SUB-ASSEMBLY


    1. A01FDFI

      Install the transfer baffle valve sub-assembly to the transfer rear chain case assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  16. INSTALL TRANSFER CASE BEARING


    1. A01FF9HE02

      Using SST and a press, install a new transfer case bearing to the transfer case sub-assembly.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07150 )
      Bearing drive in depth
      94.61 to 94.86 mm (3.725 to 3.734 in.)

  17. INSTALL TRANSFER CASE OIL SEAL


    1. A01FHOXE02

      Using SST and a hammer, install a new transfer case oil seal.

      SST
      09325-40010
      Oil Seal Drive in Depth
      2.3 to 2.7 mm (0.091 to 0.106 in.)

    2. Apply MP grease to the transfer case oil seal lip.

  18. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR


    1. A01FELFE02

      Using SST and a press, install a new transfer extension housing dust deflector to the transfer case sub-assembly.

      SST
      09950-60020   ( 09951-00910 )
      09950-70010   ( 09951-07150 )

  19. INSTALL TRANSFER FRONT CHAIN CASE


    1. A01FFKCE02
      Text in Illustration
      *1 Seal Packing
      *a Seal Width 1.0 to 1.5 mm (0.04 to 0.06 in.)

      Clean the threads of the bolts and the transfer front chain case with non-residue solvent.

    2. Apply seal packing to the transfer front chain case as shown in the illustration.

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

      Note

      Reassemble the parts within 5 minutes of applying fresh FIPG material. Otherwise, the packing (FIPG) material must be removed and reapplied.

    3. A01FE00E01

      Temporarily install the 6 bolts in several steps, and then tighten them to the specified torque.

      Torque:
      34 N*m  { 345 kgf*cm, 25 ft.*lbf }

      Tech Tips


        Bolt length:

      • Bolt A: 57 mm (2.244 in.)

      • Bolt B: 74 mm (2.913 in.)

      • Other Bolts: 45 mm (1.771 in.)

  20. INSTALL TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVE SPROCKET SUB-ASSEMBLY AND TRANSFER FRONT DRIVE CLUTCH SLEEVE SUB-ASSEMBLY


    1. Install the transfer front drive chain to the transfer drive sprocket sub-assembly and transfer front drive clutch sleeve sub-assembly.

    2. A01FICU

      Install the transfer front drive chain, transfer drive sprocket sub-assembly and transfer front drive clutch sleeve sub-assembly.

  21. INSTALL TRANSFER REAR CHAIN CASE ASSEMBLY


    1. A01FFS8E02
      Text in Illustration
      *1 Seal Packing
      *a Seal Width 1.0 to 1.5 mm (0.04 to 0.06 in.)

      Clean the threads of the bolts and the transfer rear chain case assembly with non-residue solvent.

    2. Apply seal packing to the transfer rear chain case assembly as shown in the illustration.

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

      Note

      Reassemble the parts within 5 minutes of applying fresh FIPG material. Otherwise, the packing (FIPG) material must be removed and reapplied.

    3. A01FDKZE01

      Temporarily install the 10 bolts in several steps, and then tighten them to the specified torque.

      Torque:
      Bolt A
      57 N*m  { 579 kgf*cm, 42 ft.*lbf }
      Bolt B, Bolt C and Other Bolts
      34 N*m  { 345 kgf*cm, 25 ft.*lbf }

      Tech Tips


        Bolt length:

      • Bolt A: 60 mm (2.362 in.)

      • Bolt B: 50 mm (1.969 in.)

      • Bolt C: 109 mm (4.291 in.)

      • Other Bolts: 40 mm (1.574 in.)

  22. INSTALL FLANGE YOKE ASSEMBLY


    1. Install the flange yoke assembly.

    2. A01FGOKE05
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, hold the flange yoke assembly.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    3. Using a 30 mm deep socket wrench, install a new flange yoke nut.

      Torque:
      123 N*m  { 1249 kgf*cm, 90 ft.*lbf }

    4. Using a chisel and hammer, stake the flange yoke nut.

  23. INSTALL TRANSFER REAR OUTPUT SHAFT ASSEMBLY


    1. A01FGV2

      Install the transfer rear output shaft assembly.

  24. INSTALL TRANSFER CASE SUB-ASSEMBLY


    1. A01FGFLE01
      Text in Illustration
      *1 Clamp

      Install the clamp to the transfer case sub-assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    2. A01FH3ME02
      Text in Illustration
      *1 Seal Packing
      *a Seal Width 1.0 to 1.5 mm (0.04 to 0.06 in.)

      Clean the threads of the bolts and the transfer case sub-assembly with non-residue solvent.

    3. Apply seal packing to the transfer case sub-assembly as shown in the illustration.

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

      Note

      Reassemble the parts within 5 minutes of applying fresh FIPG material. Otherwise, the packing (FIPG) material must be removed and reapplied.

    4. A01FGORE06
      Text in Illustration
      *1 Clamp

      Temporarily install the 8 bolts and clamp in several steps, and then tighten them to the specified torque.

      Torque:
      34 N*m  { 345 kgf*cm, 25 ft.*lbf }

      Tech Tips


        Bolt length:

      • Bolt A: 88 mm (3.465 in.)

      • Bolt B: 40 mm (1.574 in.)

  25. INSTALL TRANSFER CONTROL VALVE BODY ASSEMBLY


    1. A01FIR0E01
      Text in Illustration
      *1 Transfer Transmission Wire O-ring
      A01FGIV Coat with Toyota Genuine ATF WS

      Coat the transfer transmission wire O-ring with ATF.

      ATF
      Toyota Genuine ATF WS
    2. A01FISQ

      Install the transfer transmission wire with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    3. A01FDO3E02
      Text in Illustration
      *1 Connector

      Connect the connector to the transfer control solenoid assembly.

    4. Install the transfer control valve body assembly with the 4 bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  26. INSTALL TRANSFER OIL PAN SUB-ASSEMBLY


    1. A01FI1HE01
      Text in Illustration
      *1 Transfer Oil Cleaner Magnet

      Install the transfer oil cleaner magnet to the transfer oil pan sub-assembly.

    2. A01FG4WE02
      Text in Illustration
      *1 Seal Packing
      *a Seal Width 3.0 to 3.5 mm (0.12 to 0.14 in.)

      Clean the threads of the bolts and the transfer oil pan sub-assembly with non-residue solvent.

    3. Apply seal packing to the transfer oil pan sub-assembly as shown in the illustration.

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

      Note

      Reassemble the parts within 5 minutes of applying fresh FIPG material. Otherwise, the packing (FIPG) material must be removed and reapplied.

    4. A01FE4H

      Temporarily install the 9 bolts in several steps, and then tighten them to the specified torque.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }