TRANSFER ASSEMBLY REASSEMBLY
PROCEDURE
INSTALL TRANSFER LOW PLANETARY RING GEAR
Install the low planetary ring gear to the front transfer case.
-
Using a screwdriver, install the snap ring.
INSTALL PIN
-
Install the pin.
-
INSTALL COMPRESSION SPRING
Install the spring.
INSTALL TRANSFER CASE PLUG
Install the transfer case plug.
19 N*m
190 kgf*cm
14 ft.*lbf
INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER
-
Install the washer.
-
INSTALL TRANSFER DRIVE SPROCKET BEARING
Install the bearing.
INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
Install the transfer drive sprocket.
INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER
Install the output shaft spacer.
INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING
-
*1
Groove
*a
Rear
Using SST and a press, install a new bearing.
09316-60011
09316-00011
09316-00071
Note:Install the bearing so that the bearing snap ring groove faces the rear.
-
INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER
-
Install the washer.
-
INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
Install the needle roller bearing.
INSTALL TRANSFER CLUTCH HUB
Install the transfer clutch hub.
INSTALL CENTER DIFFERENTIAL CASE
-
Install the center differential case.
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INSTALL TRANSFER OUTPUT SHAFT SPACER BALL
Install the ball.
INSTALL NO. 2 TRANSFER OUTPUT SHAFT SPACER
Install the spacer.
Using a snap ring expander, install the snap ring.
INSPECT DRIVE SPROCKET RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of the drive sprocket.
Standard clearance
0.01 to 0.06 mm (0.000394 to 0.00236 in.)
Maximum clearance
0.06 mm (0.00236 in.)
If the clearance is more than the maximum, replace the drive sprocket, rear output shaft or bearing.
INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of the drive sprocket.
Standard clearance
0.15 to 0.24 mm (0.00591 to 0.00944 in.)
Maximum clearance
0.24 mm (0.00944 in.)
If the clearance is more than the maximum, replace the drive sprocket.
INSTALL TRANSFER INPUT SHAFT BEARING
-
Using SST and a press, install a new bearing with the groove facing forward.
09223-15020
09515-30010
09950-70010
09951-07100
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INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING
Select a new snap ring that allows minimal axial play.
Standard Snap Ring Thickness
Mark
Specified Condition
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.)
Using a snap ring expander, install the snap ring.
INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE
-
Using a screwdriver, install the low planetary gear spline piece and snap ring.
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INSTALL TRANSFER LOW PLANETARY GEAR BEARING
Using SST and a press, press in a new low planetary gear bearing.
09950-60010
09951-00570
09950-70010
09951-07100
Press in depth
7.7 to 8.3 mm (0.304 to 0.326 in.)
INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING
-
Apply gear oil to 2 new seal rings.
Install the 2 seal rings to the input shaft.
Note:When installing the seal ring, make sure not to expand it so that its inner diameter exceeds 65 mm (2.56 in.).
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INSTALL TRANSFER LOW PLANETARY GEAR THRUST BEARING
-
*a
Front
Install the bearing.
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INSTALL NO. 1 TRANSFER THRUST BEARING RACE
Install the thrust bearing race.
INSTALL TRANSFER INPUT SHAFT
Install the transfer input shaft.
INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER
-
Install the washer.
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INSTALL TRANSFER INPUT GEAR STOPPER BALL
Install the ball.
INSTALL TRANSFER INPUT GEAR STOPPER
Install the input gear stopper.
INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING
-
Select a new input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.00197 to 0.00590 in.) of axial play.
Standard Snap Ring Thickness
Specified Condition
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 0.100 in.)
2.55 to 2.60 mm (0.100 to 0.102 in.)
2.60 to 2.65 mm (0.102 to 0.104 in.)
2.65 to 2.70 mm (0.104 to 0.106 in.)
2.70 to 2.75 mm (0.106 to 0.108 in.)
2.75 to 2.80 mm (0.108 to 0.110 in.)
2.80 to 2.85 mm (0.110 to 0.112 in.)
2.85 to 2.90 mm (0.112 to 0.114 in.)
2.90 to 2.95 mm (0.114 to 0.116 in.)
2.95 to 3.00 mm (0.116 to 0.118 in.)
3.00 to 3.05 mm (0.118 to 0.120 in.)
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Using a snap ring expander, install the snap ring.
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INSTALL LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT SUB-ASSEMBLY
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Install the low planetary gear together with the input shaft.
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Using a snap ring expander, install the shaft snap ring.
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INSTALL TRANSFER OIL PUMP GEAR
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Install the transfer oil pump gear.
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INSTALL TRANSFER OIL PUMP BODY O-RING
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Coat a new O-ring with gear oil and install it to the oil pump body.
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INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY
-
Install the oil pump body with the 3 bolts.
7.5 N*m
76 kgf*cm
66 in.*lbf
-
INSTALL TRANSFER CASE MAGNET
INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY
-
Install the oil separator with the 3 bolts.
7.5 N*m
76 kgf*cm
66 in.*lbf
-
INSTALL FILLER PLUG
Install a new gasket and the filler plug.
37 N*m
377 kgf*cm
27 ft.*lbf
INSTALL DRAIN PLUG
Install a new gasket and the drain plug.
37 N*m
377 kgf*cm
27 ft.*lbf
INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY
-
Install a new O-ring to the transfer shift actuator assembly.
-
Install the transfer shift actuator assembly with the 3 bolts.
20 N*m
204 kgf*cm
15 ft.*lbf
Using a screwdriver and hammer, tap on the 2 snap rings.
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INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING
-
Using SST and a press, install a new input gear radial ball bearing.
09316-60011
09316-00031
-
INSTALL TRANSFER DRIVEN SPROCKET BEARING
-
Using SST and a press, install a new driven sprocket bearing.
09316-60011
09316-00071
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INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY
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Install the rear output shaft and driven sprocket to the front drive chain.
-
Install the rear output shaft, front drive chain and driven sprocket to the rear transfer case.
Tip:Check that the rear output shaft and driven sprocket turn without much effort.
Using a snap ring expander, install the snap ring.
Note:Make sure that the snap ring is firmly installed to the groove.
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INSTALL CENTER DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE
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*a
Front
Install the center differential lock fork and front drive clutch sleeve.
Note:Install the clutch sleeve in the correct direction.
Install the bolt.
24 N*m
245 kgf*cm
18 ft.*lbf
Using a screwdriver and hammer, drive in the snap ring.
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INSTALL NO. 2 TRANSFER GEAR SHIFT FORK SUB-ASSEMBLY WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE
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*a
Front
Install the No. 2 gear shift fork and high and low clutch sleeve.
Note:Install the clutch sleeve in the correct direction.
Install the bolt.
24 N*m
245 kgf*cm
18 ft.*lbf
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INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
Install the needle roller bearing to the input shaft.
INSTALL TRANSFER OUTPUT SHAFT SPACER
Install the transfer output shaft spacer to the input shaft.
INSTALL REAR TRANSFER CASE
-
*1
Seal Packing
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 is reused, 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.
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Install the clamp and rear transfer case with the 12 bolts.
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.
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INSTALL COLLAR
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Install the collar.
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INSTALL TRANSFER OUTPUT SHAFT WASHER
Install the 2 washers.
INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
-
*1
Seal Packing
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 is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the housing contact surface, 2) clean off any remaining old seal packing from the housing contact surface, and 3) reapply seal packing to the housing.
Apply adhesive to the threads of the bolts.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
-
Install the extension housing with the 5 bolts.
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.
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INSTALL TRANSFER CASE REAR OIL SEAL
INSTALL REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
-
Using SST and a hammer, tap in a new oil seal.
09950-60010
09951-00320
09950-70010
09951-07100
Coat the lip of the oil seal with MP grease.
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INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
-
*a
Rear
Apply gear oil to the connecting areas of the companion flange and output shaft.
Install the companion flange to the output shaft.
Using SST to hold the companion flange, install a new lock nut.
09330-00021
118 N*m
1203 kgf*cm
87 ft.*lbf
-
*a
CORRECT
*b
INCORRECT
Using a chisel and hammer, stake the lock nut.
Note:Securely stake the shaft to the lock nut groove.
Be careful not to damage the parts around the lock nut.
Do not apply excessive force to the shaft.
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INSTALL TRANSFER CASE FRONT OIL SEAL
INSTALL FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
-
Using SST and a hammer, tap in a new oil seal.
09950-60010
09951-00320
09950-70010
09951-07100
Coat the lip of the oil seal with MP grease.
-
INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
*a
Front
Apply gear oil to the connecting areas of the companion flange and driven sprocket.
Install the companion flange to the driven sprocket.
Using SST to hold the companion flange, install a new lock nut.
09330-00021
118 N*m
1203 kgf*cm
87 ft.*lbf
-
*a
CORRECT
*b
INCORRECT
Using a chisel and hammer, stake the lock nut.
Note:Securely stake the shaft to the lock nut groove.
Be careful not to damage the parts around the lock nut.
Do not apply excessive force to the shaft.
INSTALL BREATHER OIL DEFLECTOR
Install the oil deflector.
INSTALL TRANSFER CASE COVER SUB-ASSEMBLY
-
Install the case cover with the 4 bolts.
18 N*m
184 kgf*cm
13 ft.*lbf
-
INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
-
Using SST and a hammer, tap in a new oil seal until its surface is flush with the retainer upper surface.
09950-60010
09951-00590
09950-70010
09951-07100
Coat the lip of the oil seal with MP grease.
-
INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY
-
*1
Seal Packing
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 is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the retainer contact surface, 2) clean off any remaining old seal packing from the retainer contact surface, and 3) reapply seal packing to the retainer.
Apply sealant to the bolt threads.
Sealant
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
-
Install the retainer with the 5 bolts.
12 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.
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INSTALL HOSE
Attach the clamp and install the hose.