TRANSFER ASSEMBLY REASSEMBLY


  1. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY (for A.D.D. Manual Shift Type)

    A01E15GE01

    1. Apply gear oil to the connecting areas of the clutch sleeve and drive sprocket.

    2. Install the clutch sleeve and 3 shifting keys to the drive sprocket with the 2 shifting key springs.

      Note


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

      • Set the key springs so that their openings do not overlap, as shown in the illustration.

      • Make sure that the key springs are firmly connected to the shifting keys.

      • Make sure that the clutch sleeve and drive sprocket move smoothly.

    3. Apply gear oil to the front drive synchronizer ring's taper cone side.

    4. A01DZLBE01

      Install the front drive synchronizer ring.

    5. Apply gear oil to the output shaft and needle roller bearing.

    6. Install the needle roller bearing in the drive sprocket.

    7. Install the drive sprocket (with clutch sleeve).

    8. Install the ball. Install the spacer so that it is aligned with the ball.

  2. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY (for Normal Shift Type)

    A01E16QE01

    1. Apply gear oil to the connecting areas of the clutch sleeve and drive sprocket.

    2. Install the clutch sleeve to the drive sprocket.

      Note


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

      • Make sure that the clutch sleeve and drive sprocket move smoothly.

    3. A01DXOZE01

      Apply gear oil to the output shaft and needle roller bearing.

    4. Install the needle roller bearing in the drive sprocket.

    5. Install the drive sprocket (with clutch sleeve).

    6. Install the ball. Install the spacer so that it is aligned with the ball.

  3. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING


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

    2. A01DW08E01

      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 )

  4. CHECK TRANSFER DRIVE SPROCKET THRUST CLEARANCE

    A01E2JF

    1. Using a feeler gauge, measure the thrust clearance.

      Standard thrust clearance
      0.10 to 0.25 mm (0.0039 to 0.0098 in.)
      Maximum thrust clearance
      0.25 mm (0.0098 in.)

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

  5. INSTALL TRANSFER HIGH & LOW CLUTCH SLEEVE (for Manual Transmission)

    A01DWVXE01

    1. Apply gear oil to the connecting areas of the clutch sleeve and clutch hub.

    2. Install the clutch sleeve and 3 shifting keys to the clutch hub with the 2 shifting key springs.

      Note


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

      • Set the key springs so that their openings do not overlap, as shown in the illustration.

      • Make sure that the key springs are firmly connected to the shifting key.

      • Make sure that the clutch sleeve and clutch hub move smoothly.

  6. INSTALL TRANSFER HIGH & LOW CLUTCH SLEEVE (for Automatic Transmission)

    A01E0JXE01

    1. Apply gear oil to the connecting areas of the clutch sleeve and clutch hub.

    2. Install the clutch to the clutch hub.

      Note


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

      • Make sure that the clutch sleeve and clutch hub move smoothly.

  7. INSTALL TRANSFER CLUTCH HUB

    A01E1C5E01

    1. M/T:

      Apply gear oil to the connecting areas of a new key retainer and the output shaft.

    2. M/T:

      Using SST and a hammer, tap in the key retainer.

      SST
      09316-60011   ( 09316-00011 )

      Note

      Be careful not to deform or damage the key retainer.

    3. Apply gear oil to the connecting areas of the clutch hub and output shaft.

    4. A01DW2U

      Using a press, press in the clutch hub.

  8. INSTALL TRANSFER OUTPUT SHAFT SHAFT SNAP RING

    A01E330

    1. Select a new snap ring that allows the minimum axial free play.

      Standard snap ring thickness
      Mark Specified Condition
      K 2.00 to 2.05 mm (0.0787 to 0.0807 in.)
      L 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
      A 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      B 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
      C 2.20 to 2.25 mm (0.0866 to 0.0886 in.)
      D 2.25 to 2.30 mm (0.0886 to 0.0906 in.)
      E 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      F 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
      G 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
      H 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      J 2.50 to 2.55 mm (0.0984 to 0.1004 in.)

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

      Note

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

  9. INSTALL TRANSFER LOW PLANETARY RING GEAR

    A01DVDOE01

    1. Install the ring gear to the case front.

      Note

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

    2. A01E197

      Using a screwdriver, install the snap ring.

      Note

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

  10. INSTALL PIN

    A01DXZ4E01

  11. INSTALL COMPRESSION SPRING

  12. 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 plug.

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

  13. INSTALL TRANSFER LOW PLANETARY GEAR BEARING

    A01DW4RE01

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

      SST
      09950-60010   ( 09951-00570 )
      09950-70010   ( 09951-00710 )
      Bearing depth
      7.7 to 8.3 mm (0.303 to 0.327 in.)

  14. INSTALL TRANSFER INPUT SHAFT BEARING

    A01DWG6E01

    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 )

  15. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING

    A01DW9K

    1. Select a new snap ring that allows 0.1 mm (0.004 in.) or less of axial free 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 (o.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.)

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

      Note

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

  16. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING

    A01E1AB

    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.

  17. INSTALL TRANSFER LOW PLANETARY GEAR BEARING

    A01DZG3E01

    1. Install the bearing to the low planetary gear.

      Note

      Make sure to install the bearing in the correct direction.

  18. INSTALL NO. 1 TRANSFER THRUST BEARING RACE


    1. Install the bearing race to the low planetary gear.

  19. INSTALL TRANSFER INPUT SHAFT


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

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

  20. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER

    A01E0TDE02

    1. Apply gear oil to the washer.

    2. Install the washer to the low planetary gear.

  21. INSTALL TRANSFER INPUT GEAR STOPPER BALL


    1. Install the ball to the low planetary gear.

  22. INSTALL TRANSFER INPUT GEAR STOPPER


    1. Install the stopper to the low planetary gear.

  23. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING

    A01DVS1

    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
      Mark Specified Condition
      A 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      B 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
      C 2.20 to 2.25 mm (0.0866 to 0.0886 in.)
      D 2.25 to 2.30 mm (0.0886 to 0.0906 in.)
      E 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      F 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
      G 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
      H 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      J 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
      K 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
      L 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
      M 2.65 to 2.70 mm (0.1043 to 0.1063 in.)
      N 2.70 to 2.75 mm (0.1063 to 0.1083 in.)
      P 2.75 to 2.80 mm (0.1083 to 0.1102 in.)
      Q 2.80 to 2.85 mm (0.1102 to 0.1122 in.)
      R 2.85 to 2.90 mm (0.1122 to 0.1142 in.)
      S 2.90 to 2.95 mm (0.1142 to 0.1161 in.)
      T 2.95 to 3.00 mm (0.1161 to 0.1181 in.)
      U 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.

  24. INSTALL TRANSFER CASE OIL SEAL

    A01E2Z8E01

    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
      Oil seal depth
      -0.5 to 0.5 mm (-0.020 to 0.020 in.)

      Note

      Be careful not to damage the case front.

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

    3. A01DXVIE01

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

      SST
      09316-60011
      Oil seal depth
      -0.5 to 0.5 mm (-0.020 to 0.020 in.)

      Note

      Be careful not to damage the case front.

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

  25. INSTALL FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING

    A01E2YH

    1. Apply gear oil to the bearing.

    2. Install the bearing to the low planetary gear.

  26. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE

    A01DWXE

    1. Install the gear spline piece to the low planetary gear.

    2. A01DVJ0

      Using a screwdriver, install the snap ring.

      Note

      Be careful not to damage the gear spline piece.

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

    A01DWT0

    1. Install the low planetary gear with input shaft.

      Tech Tips

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

    2. A01DUYF

      Using a snap ring expander, install the snap ring.

      Note

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

  28. INSTALL FRONT TRANSFER DRIVE CLUTCH SYNCHRONIZER RING (for Manual Transmission)

    A01E1N3

    1. Apply gear oil to the synchronizer ring's tapered cone side.

    2. Install the synchronizer ring to the low planetary gear.

  29. INSTALL TRANSFER OIL PUMP GEAR

    A01E03N

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

    2. Install the oil pump gear with the nut.

  30. INSTALL TRANSFER OIL PUMP BODY O-RING

    A01E03B

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

  31. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY

    A01DW0OE01

    1. Install the oil pump body with the 3 bolts.

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

  32. INSTALL TRANSFER CASE MAGNET

    A01DZ6Z

  33. 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 }

  34. 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 }

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


    1. Install a new gasket and the drain plug.

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

  36. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING

    A01E28XE01

    1. Apply gear oil to the contact surfaces 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.

  37. INSTALL TRANSFER DRIVEN SPROCKET BEARING

    A01DXR4

    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.

  38. INSTALL REAR TRANSFER OUTPUT SHAFT, TRANSFER FRONT DRIVE CHAIN AND TRANSFER DRIVEN SPROCKET

    A01DX5PE01

    1. Mount the rear case in a vise.

      Note

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

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

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

      Note

      When installing the output shaft, make sure that the installation of the synchronizer ring, sleeve and shifting keys are not affected.

      Tech Tips

      Check that the output shaft and driven sprocket turn smoothly.

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

    4. A01E2K2

      Using a snap ring expander, install the snap ring.

      Note

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

  39. INSTALL TRANSFER HIGH AND LOW SHIFT FORK SHAFT

    A01DY4RE01

    1. Apply gear oil to the connecting areas of the shift fork shaft and each part.

    2. Install the shift fork shaft and No. 2 gear shift fork.

      Note

      Make sure to install the shift fork shaft and No. 2 gear shift fork in the correct direction.

    3. Install the spring and ball to the hole.

    4. Apply adhesive to the threads of the plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    5. Using a hexagon wrench, install the plug.

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

  40. INSTALL FRONT TRANSFER DRIVE SHIFT FORK SHAFT

    A01E321

    1. Apply gear oil to the straight pin.

    2. Install the straight pin to the hole.

    3. A01DXZGE01

      Apply gear oil to the connecting areas of the shift fork shaft and each part.

    4. Install the shift fork shaft, No. 1 gear shift fork, spring and shift shaft stopper.

      Note

      Make sure to install the shift fork shaft, No. 1 gear shift fork and shift shaft stopper in the correct direction.

    5. A01E1IME01

      Using a pin punch and hammer, install the 2 slotted pins.

      Note

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

    6. Install the spring and ball to the hole.

    7. Apply adhesive to the threads of the plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    8. Using a hexagon wrench, install the plug.

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

  41. INSTALL REAR TRANSFER CASE

    A01DYAZE05

    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 rear 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) reapply seal packing to the rear case.

    2. A01DWKD

      Install the clamp 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.

  42. INSTALL TRANSFER SPEEDOMETER DRIVE GEAR

  43. INSTALL TRANSFER OUTPUT SHAFT WASHER


    1. Install the 2 output washers.

  44. INSTALL TRANSFER COVER OIL SEAL

    A01E2T4E01

    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.

  45. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY

    A01DZZEE05

    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 housing's contact surface, 2) clean off any remaining old seal packing from the housing's contact surface, and 3) reapply seal packing to the housing.

    2. Apply adhesive to the threads of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the extension housing with the 5 bolts.

      Torque:
      12 N*m  { 22 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.

  46. INSTALL SPEEDOMETER SENSOR


    1. A01E1VA

      Coat a new O-ring with gear oil and install it to the speedometer sensor.

    2. Install the speedometer sensor to the transfer with the bolt.

      Torque:
      12 N*m  { 177 kgf*cm, 8 ft.*lbf }

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

    A01DW03E01

    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.

  48. 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.

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

    A01DVEBE01

    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, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )
      Torque:
      118 N*m  { 1,203 kgf*cm, 87 ft.*lbf }
    4. A01E0ZKE01

      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.

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


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

    2. Using SST, install the companion flange (rear) in the same way as the companion flange (front).

      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 }

  51. INSTALL BREATHER OIL DEFLECTOR SUB-ASSEMBLY

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

    A01DZDG

    1. Install the retainer with the 4 bolts.

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

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

    A01DV77

    1. Install the case cover with the 4 bolts.

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

  54. INSTALL TRANSFER COVER OIL SEAL

    A01DWZHE01

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

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

      Note

      Be careful not to damage the bearing retainer.

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

  55. INSTALL TRANSFER BEARING RETAINER SUB-ASSEMBLY

    A01DX0GE05

    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 retainer's contact surface, 2) clean off any remaining old seal packing from the retainer's contact surface, and 3) reapply seal packing to the retainer.

    2. Apply adhesive to the bolt threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the 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.

  56. INSTALL TRANSFER GEAR SHIFT HEAD (for Adapter on Type)

    A01E0AQE01

    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. A01DX3BE01

      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.

  57. INSTALL TRANSFER INDICATOR SWITCH

    A01DW25E01

    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 A/T
      No. 2 Indicator switch (L4 position) for A/T or M/T w/ ABS
      No. 3 Indicator switch (4WD) for A/T and M/T