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Transfer Assembly: Disassembly

WARNING: This page is about a different car, the 2007 Toyota Tacoma. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Remove the 4 bolts and the case cover sub-assembly.
    Fig 1: Removing Transfer Case Cover Sub-Assembly
    G04369233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE BREATHER OIL DEFLECTOR SUB-ASSEMBLY 
  3. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY 
    1. Remove the 5 bolts and the front bearing retainer sub-assembly.

    HINT:

    If necessary, tap the retainer sub-assembly with a plastic hammer to remove it.

    Fig 2: Removing Transfer RH Bearing Retainer Sub-Assembly
    G04369234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL (for R155F/A750F) 
    1. Using a screwdriver and hammer, remove the transfer RH bearing retainer oil seal.
  5. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL (for RA60F) 
    1. Using a screwdriver and hammer, remove the 2 transfer RH bearing retainer oil seals.
  6. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut.
    2. Using SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut.

      SST 09330-00021 

      Fig 3: Holding Output Shaft Companion Flange Lock Nut
      G04369235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the output shaft companion flange sub-assembly (front side).

    SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) 

    Fig 4: Removing Output Shaft Companion Flange Sub-Assembly (Front Side)
    G04369236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using a screwdriver and hammer, remove the companion flange oil seal.
  8. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Remove the rear output shaft companion flange sub-assembly using the same procedure as for the front output shaft companion flange sub-assembly (rear side).

    SST 09330-00021, 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) 

  9. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using a screwdriver and hammer, remove the companion flange oil seal.
  10. REMOVE SPEEDOMETER DRIVEN GEAR SUB-ASSEMBLY (for R155F/RA60F) 
    1. Remove the bolt and speedometer driven gear w/ sensor.
  11. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (for A750F) 
    1. Remove the bolt and speedometer hole cover sub-assembly.
  12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY FRONT 
    1. Remove the 5 bolts and extension housing sub-assembly.

    HINT:

    If necessary, tap the extension housing sub-assembly with a plastic hammer to remove it.

    Fig 5: Removing Transfer Extension Housing Sub-Assembly Front
    G04369237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using a screwdriver and hammer, remove the type T oil seal.
  14. REMOVE TRANSFER OUTPUT WASHER 
  15. REMOVE TRANSFER SPEEDOMETER DRIVE GEAR 
    1. Remove the speedometer drive gear.
    2. Using a magnetic finger, remove the speedometer drive gear ball.
  16. REMOVE TRANSFER REAR CASE 
    1. Remove the 12 bolts and 2 brackets.
    2. Remove the transfer case rear.

    HINT:

    If necessary, tap the transfer case rear with a plastic hammer to remove it.

    Fig 6: Removing Transfer Rear Case
    G04369238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT 
    1. Using a hexagon wrench (6 mm), remove the 2 shift detent ball spring plugs, 2 shift fork compression springs and 2 shift detent balls.
      Fig 7: Removing Shift Detent Ball Spring Plugs, Shift Fork Compression Springs & Shift Detent Balls
      G04369239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers and a hammer, tap out the 2 shift fork shaft snap rings.
      Fig 8: Tapping Out Shift Fork Shaft Snap Rings Using Screwdrivers & Hammer
      G04369240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and shift shaft stopper.
      Fig 9: Removing Shift Shaft Stopper
      G04369241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. To pull out the shift fork shaft, shift the shift fork No. 1 and No. 2 to the positions shown in Fig 10.
    5. Pull out the shift fork shaft.
      Fig 10: Pulling Out Shift Fork Shaft
      G04369242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a magnetic finger, remove the 2 shift inter lock pins.
    Fig 11: Removing Shift Inter Lock Pins
    G04369243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE REAR OUTPUT SHAFT ASSEMBLY, FRONT DRIVE CHAIN, DRIVEN SPROCKET ASSEMBLY, SHIFT FORK NO. 1 AND NO. 2 
    1. Using 2 screwdrivers and a hammer, tap out the shift fork shaft snap ring.

      HINT:

      Remove only the snap ring on the front side of the shift fork shaft.

      Fig 12: Tapping Out Shift Fork Shaft Snap Ring Using Screwdrivers & Hammer
      G04369244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, remove the output shaft snap ring.
      Fig 13: Removing Output Shaft Snap Ring Using Snap Ring Expander
      G04369245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mount the transfer case rear in a vise.
    4. Using a plastic hammer, carefully tap the transfer case rear and remove the rear output shaft assembly, driven sprocket assembly, front drive chain, shift fork No. 1 and No. 2.
    5. Remove the driven sprocket assembly, front drive chain, shift fork No. 1 and No. 2 from the rear output shaft assembly.
    Fig 14: Removing Driven Sprocket Assembly
    G04369246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY 
    1. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring.
    2. Remove the 3 bolts and shift actuator assembly.
    Fig 15: Removing Shift Fork Shaft Snap Ring Using Screwdrivers & Hammer
    G04369247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE TRANSFER INDICATOR SWITCH NO. 1 
    1. Remove the O-ring, the 2 indicator switches No. 1 and 2 gaskets.
    Fig 16: Removing Transfer Indicator Switch No. 1
    G04369248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    1. Using SST and a press, remove the driven sprocket bearing.

    SST 09527-10011 

    Fig 17: Removing Driven Sprocket Bearing Using SST & Press
    G04369249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING 
    1. Using SST, a press and steel bar, remove the input gear radial ball bearing.

    SST 09555-55010 

    Fig 18: Removing Transfer Input gear Radial Ball Bearing
    G04369250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE TRANSFER CASE PLUG 
    1. Remove the transfer case plug No. 1 (filler plug) and gasket.
  24. REMOVE TRANSFER CASE PLUG 
    1. Remove the transfer case plug (drain plug) and gasket.
  25. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Remove the 3 bolts and oil separator sub-assembly.
    Fig 19: Removing Oil Separator Sub-Assembly
    G04369251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE TRANSFER CASE MAGNET 
  27. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Remove the 3 bolts and oil pump body sub-assembly.
    Fig 20: Removing Transfer Oil Pump Body Sub-Assembly
    G04369252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE TRANSFER OIL PUMP GEAR 
  29. REMOVE TRANSFER OIL PUMP BODY O-RING 
    1. Using a screwdriver, remove the oil pump body O-ring.
    Fig 21: Removing Oil Pump Body O-Ring Using Screwdriver
    G04369253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY 
    1. Using a snap ring expander, remove the low planetary gear bearing shaft snap ring.
      Fig 22: Removing Low Planetary Gear Bearing Shaft Snap Ring
      G04369254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the low planetary gear assembly with input shaft assembly.
    Fig 23: Removing Low Planetary Gear Assembly With Input Shaft Assembly
    G04369255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE TRANSFER CASE PLUG 
    1. Remove the case plug.
    2. Using a magnetic finger, remove the spring and pin.
    Fig 24: Removing Transfer Case Plug
    G04369256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    1. Using a screwdriver, remove the hole snap ring.
    2. Remove the low planetary ring gear from the front case.
    Fig 25: Removing Transfer Case Oil Seal Using Screwdriver & Hammer
    G04369257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE TRANSFER CASE OIL SEAL 
    1. Using a screwdriver and hammer, remove the transfer case oil seal.
  34. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, remove the low planetary gear shaft snap ring.
      Fig 26: Removing Low Planetary Gear Shaft Snap Ring Using Screwdriver
      G04369258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the low planetary gear spline piece.
    Fig 27: Removing Low Planetary Gear Spline Piece
    G04369259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
    Fig 28: Removing Transfer Output Shaft Front Needle Roller Bearing
    G04369260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    1. Using a snap ring expander, remove the input gear stopper shaft snap ring.
    Fig 29: Removing Input Gear Stopper Shaft Snap Ring Using Snap Ring Expander
    G04369261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE TRANSFER INPUT GEAR STOPPER 
  38. REMOVE TRANSFER INPUT GEAR STOPPER BALL 
  39. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER 
    Fig 30: Removing Manual Transfer Planetary Carrier Washer
    G04369262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE TRANSFER INPUT SHAFT 
  41. REMOVE TRANSFER NO. 1 THRUST BEARING RACE 
  42. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    Fig 31: Removing Transfer Low Planetary Gear Bearing
    G04369263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE TRANSFER NO. 1 INPUT SHAFT SEAL RING 
    1. Remove the 2 seal rings No. 1.
    Fig 32: Removing Seal Rings
    G04369264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE TRANSFER INPUT SHAFT BEARING 
    1. Using a snap ring expander, remove the input bearing shaft snap ring.
    2. Using SST and a press, remove the input shaft bearing.

    SST 09554-30011, 09555-55010 

    Fig 33: Removing Input Shaft Bearing Using SST & Press
    G04369265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    1. Using SST, remove the low planetary gear bearing.

    SST 09612-65014 (09612-01030, 09612-01050) 

    NOTE: Hang SST securely to the clearance between the bearing and the low planetary gear.
    Fig 34: Removing Low Planetary Gear Bearing Using SST
    G04369266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSPECT DRIVE SPROCKET THRUST CLEARANCE 
    1. Using a feeler gauge, measure the drive sprocket thrust clearance.

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

    Maximum clearance: 0.25 mm (0.0098 in.) 

    If the clearance exceeds the maximum, replace the drive sprocket.

    Fig 35: Measuring Drive Sprocket Thrust Clearance Using Feeler Gauge
    G04369267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE TRANSFER CLUTCH HUB 
    1. Using a snap ring expander, remove the clutch hub shaft snap ring.
      Fig 36: Removing Clutch Hub Shaft Snap Ring Using Snap Ring Expander
      G04369268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the high and low clutch sleeve.
    3. Using a press, remove the clutch hub.
    Fig 37: Removing Clutch Hub Using Press
    G04369269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST and a press, remove the bearing.

    SST 09555-55010 

    Fig 38: Removing Bearing Using SST & Press
    G04369270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
  1. Remove the output shaft spacer and output shaft spacer ball.
  2. Remove the drive sprocket sub-assembly, synchronizer inner ring, center ring, outer ring and drive clutch sleeve together.
  3. Remove the drive sprocket bearing.
  4. Remove the synchronizer inner ring, center ring, outer ring and drive clutch sleeve.
  5. Remove the 3 synchromesh shifting keys No. 1 and the 2 synchromesh shifting key springs No. 1.
Fig 39: Removing Transfer Drive Sprocket Sub-Assembly
G04369271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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