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Transfer Assembly: Disassembly: Disassembly

  1. REMOVE DYNAMIC DAMPER 
      Fig 1: Removing The Bolt, 2 Washers And Dynamic Damper
      GTY262815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt, 2 washers and dynamic damper from the rear transfer case.
  2. REMOVE TRANSFER CASE PLUG 
      Fig 2: Removing The 2 Case Plugs And 2 O-Rings
      GTY275962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 6 mm hexagon socket wrench, remove the 2 case plugs and 2 O-rings from the front transfer case.
  3. REMOVE FILLER PLUG 
      Fig 3: Removing The Filler Plug And Gasket
      GTY257316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 10 mm hexagon socket wrench, remove the filler plug and gasket from the rear transfer case.
  4. REMOVE TRANSFER DRAIN PLUG 
      Fig 4: Removing The Drain Plug And O-Ring From The Front Transfer Case
      GTY257315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 10 mm hexagon socket wrench, remove the drain plug and O-ring from the front transfer case.
  5. REMOVE TRANSFER CASE BREATHER PLUG 
      Fig 5: Identifying Breather Plug
      GTY136389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the breather plug from the front transfer case.
  6. REMOVE NO. 2 TRANSFER CASE PLUG 
      Fig 6: Remove The Case Plug And Gasket
      GTY262817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 17 mm straight hexagon wrench, remove the case plug and gasket from the rear transfer case.
  7. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
      Fig 7: Hold The Companion Flange In Place
      GTY121806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, hold the companion flange in place.
      • SST: 09213-58014 
      • SST: 09330-00021 

      HINT: 

      Use bolts of size M8 x P1.25 with a length of approximately 55 mm (2.16 in.) or equivalent to secure the companion flange.

      2. Fig 8: Removing The Companion Flange Bolt And Companion Flange
      GTY263046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the companion flange bolt and companion flange from the transfer assembly.
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
  8. REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY 
      Fig 9: Loosening Staked Part Of Transfer Output Shaft Nut
      GTY289476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Completely loosen the staked part of the transfer output shaft nut.
      • Do not damage the threads of the No. 1 differential case.
      • Use SST with the tapered surface facing the No. 1 differential case.
      • Do not grind the end of SST with a grinder or other tool.
    1. Using SST and a hammer, loosen the staked part of the transfer output shaft nut.
      • SST: 09930-00010 
      2. Fig 10: Hold The Companion Flange In Place
      GTY273360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, hold the companion flange in place.
      • SST: 09330-00021 
      • SST: 09950-30012 
        1. 09955-03040
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
    3. Using a 30 mm socket wrench, remove the transfer output shaft nut.
      4. Fig 11: Removing The Companion Flange
      GTY268734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, remove the companion flange.
      • SST: 09950-30012 
        1. 09951-03010
        2. 09953-03010
        3. 09954-03010
        4. 09955-03040
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
  9. REMOVE TRANSFER EXTENSION HOUSING OIL SEAL 
      Fig 12: Identifying Oil Seal
      GTY135111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the surface of the transfer extension housing that contacts the oil seal.

    1. Using SST, remove the oil seal.
      • SST: 09308-00010 
  10. REMOVE NO. 1 DIFFERENTIAL CASE HOLE SNAP RING 
      Fig 13: Identifying Snap Ring
      GTY127859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using needle-nose pliers, remove the snap ring from the extension housing.
  11. REMOVE TRANSFER EXTENSION HOUSING 
      Fig 14: Removing The 11 Bolts And Bracket
      GTY262820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 11 bolts and bracket.
      2. Fig 15: Identifying Extension Housing
      GTY127860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surface of the extension housing or rear transfer case.

    2. Using an oil pan seal cutter, remove the extension housing.
  12. REMOVE NO. 1 TRANSFER THRUST BEARING RACE 
      Fig 16: Removing The Bearing Race
      GTY287279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the surface which contacts the bearing race.

    1. Using a screwdriver, remove the bearing race from the extension housing.
      TEXT IN ILLUSTRATION

      *1 Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

  13. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING 
      Fig 17: Removing The Bearing (Outer Race)
      GTY143330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, remove the bearing (outer race) from the extension housing.
      • SST: 09950-60010 
        1. 09951-00460
      • SST: 09950-70010 
        1. 09951-07100

      HINT: 

      The bearing (inner race) is removed from the No. 1 differential case sub-assembly.

  14. REMOVE TRANSFER OUTPUT SHAFT WASHER 
      Fig 18: Removing The 2 Shaft Washers
      GTY262830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 shaft washers from the No. 1 differential case.
  15. REMOVE DIFFERENTIAL CASE NEEDLE ROLLER BEARING 
      Fig 19: Removing The Bearing
      GTY262831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bearing from the No. 1 differential case.
  16. REMOVE NO. 2 TRANSFER THRUST BEARING RACE 
      Fig 20: Removing The Bearing Race
      GTY262832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bearing race from the No. 1 differential case.
  17. REMOVE TRANSFER OUTPUT SHAFT SHIM 
      Fig 21: Removing The Shim
      GTY257946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the shim from the No. 1 differential case.
  18. REMOVE NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY 
    1. Remove the No. 1 differential case from the rear transfer case.
  19. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING 
      Fig 22: Removing The Bearing (Inner Race)
      GTY261288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the bearing (inner race) from the No. 1 differential case.
      • SST: 09950-00020 
      • SST: 09950-00030 
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
  20. REMOVE BREATHER OIL DEFLECTOR 
      Fig 23: Removing The 2 Bolts And Oil Deflector
      GTY283534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 bolts and oil deflector.
  21. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
      Fig 24: Removing The Snap Ring
      GTY262833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, remove the snap ring from the input shaft.
  22. REMOVE TRANSFER INPUT GEAR STOPPER 
      Fig 25: Removing The Gear Stopper
      GTY262834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the gear stopper from the input shaft.
  23. REMOVE REAR TRANSFER CASE 
      Fig 26: Removing The 7 Bolts
      GTY262755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 7 bolts and rear transfer case.
  24. REMOVE TRANSFER IDLER GEAR ASSEMBLY 
      Fig 27: Removing The Idler Gear
      GTY262757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the idler gear from the front transfer case.
  25. REMOVE TRANSFER OIL PUMP DRIVE SHAFT 
      Fig 28: Removing The Oil Pump Drive Shaft
      GTY283515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the oil pump drive shaft from the front transfer case.
  26. REMOVE TRANSFER COUNTER GEAR ASSEMBLY 
      Fig 29: Removing The Counter Gear
      GTY283443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the counter gear from the front transfer case.
  27. REMOVE TRANSFER FRONT DRIVE GEAR ASSEMBLY 
      Fig 30: Removing The Drive Gear
      GTY262444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the drive gear from the front transfer case.
  28. REMOVE TRANSFER FRONT DRIVE GEAR PIN 
      Fig 31: Removing The Drive Gear Pin
      GTY262442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the drive gear pin from the front transfer case.
  29. REMOVE TRANSFER INPUT SHAFT 
      Fig 32: Removing The Input Shaft
      GTY283480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the input shaft from the drive gear.
  30. REMOVE TRANSFER OIL SEAL RING 
      Fig 33: Removing The Oil Seal Ring
      GTY283482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the oil seal ring from the input shaft.
  31. REMOVE DRIVE PINION COMPANION FLANGE OIL SEAL 
      Fig 34: Tap Out The Oil Seal
      GTY263335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.
      TEXT IN ILLUSTRATION

      *1 Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

  32. REMOVE TRANSFER IDLER GEAR BEARING 
      Fig 35: Removing The Idler Gear Bearing (Inner Race)
      GTY254658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. for Front Transfer Case Side:

      Using SST, remove the idler gear bearing (inner race) from the idler gear.

      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04021
        6. 09957-04010
        7. 09958-04011
      • SST: 09950-60010 
        1. 09951-00420
        2. 09951-00540
        3. 09952-06010
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
      2. Fig 36: Idler Gear Bearing (Inner Race)
      GTY267019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Rear Transfer Case Side:

      Using SST, remove the idler gear bearing (inner race) from the idler gear.

      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04021
        6. 09957-04010
        7. 09958-04011
      • SST: 09950-60010 
        1. 09951-00440
        2. 09951-00540
        3. 09952-06010
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
  33. REMOVE TRANSFER COUNTER GEAR BEARING 
      Fig 37: Removing The Counter Gear Bearing (Inner Race)
      GTY257958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. for Front Transfer Case Side:

      Using SST, remove the counter gear bearing (inner race) from the counter gear.

      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-40011 
        1. 09957-04010
      • SST: 09950-60010 
        1. 09951-00280
        2. 09951-00440
        3. 09952-06010
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
      2. Fig 38: Removing The Counter Gear Bearing (Inner Race)
      GTY278322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Rear Transfer Case Side:

      Using SST, remove the counter gear bearing (inner race) from the counter gear.

      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-40011 
        1. 09957-04010
      • SST: 09950-60010 
        1. 09951-00360
        2. 09951-00500
        3. 09952-06010
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
  34. REMOVE TRANSFER OIL SEPARATOR 
      Fig 39: Removing the 3 Bolts And Oil Separator
      GTY265404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 bolts and oil separator from the front transfer case.
  35. REMOVE NO. 1 TRANSFER OIL STRAINER 
      Fig 40: Remove The Oil Strainer
      GTY265405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the oil strainer from the front transfer case.
  36. REMOVE TRANSFER OIL COOLER RELIEF VALVE 
      Fig 41: Removing The Bolt, Relief Valve Plate And Relief Valve Compression Spring
      GTY124040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful to prevent the relief valve compression spring from jumping out.

    1. Remove the bolt, relief valve plate and relief valve compression spring from the front transfer case.
      2. Fig 42: Identifying Relief Valve
      GTY129858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a magnet hand, remove the relief valve from the front transfer case.
  37. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
      Fig 43: Tap Out The Oil Seal
      GTY255640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the surface which contacts the oil seal.

    1. Using a screwdriver and hammer, tap out the oil seal from the front transfer case.
      TEXT IN ILLUSTRATION

      *1 Protective Tape
  38. REMOVE TRANSFER IDLER GEAR BEARING 
      Fig 44: Removing The Idler Gear Bearing (Outer Race)
      GTY277086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. for Front Transfer Case Side:

      Using SST, remove the idler gear bearing (outer race) from the front transfer case.

      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04071
        6. 09957-04010
      • SST: 09950-60010 
        1. 09951-00290
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
      2. Fig 45: Removing The Idler Gear Bearing (Outer Race)
      GTY277324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Rear Transfer Case Side:

      Using SST, remove the idler gear bearing (outer race) from the rear transfer case.

      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04071
        6. 09957-04010
      • SST: 09950-60010 
        1. 09951-00380
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
    3. Remove the idler gear shim from the rear transfer case.
  39. REMOVE TRANSFER OIL PUMP PLATE SUB-ASSEMBLY 
    1. Using an air gun, gradually apply air and remove the transfer oil pump plate from the front transfer case.
    2. Remove the transfer oil pump plate pin from the transfer oil pump plate.
    3. Remove the drive rotor and driven rotor from the front transfer case.
  40. REMOVE TRANSFER COUNTER GEAR BEARING 
      Fig 46: Removing The Bearing (Outer Race)
      GTY276364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. for Front Transfer Case Side:

      Using SST, remove the bearing (outer race) from the front transfer case.

      • SST: 09612-65014 
        1. 09612-01020
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
      2. Fig 47: Removing The Bearing (Outer Race)
      GTY274997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Rear Transfer Case Side:

      Using SST, remove the bearing (outer race) from the rear transfer case.

      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04071
        6. 09957-04010
      • SST: 09950-60010 
        1. 09951-00420
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
    3. Remove the counter gear shim from the rear transfer case.
  41. REMOVE FORWARD CLUTCH DRAM OIL SEAL RING 
      Fig 48: Removing The Oil Seal Ring
      GTY265408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the oil seal ring from the sleeve.
  42. REMOVE TRANSFER FRONT CASE OIL SEAL 
      Fig 49: Pry Out The Oil Seal
      GTY259009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the surface which contacts the oil seal.

    1. Using a screwdriver, pry out the oil seal from the front transfer case.
      TEXT IN ILLUSTRATION

      *1 Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

  43. REMOVE TRANSFER FRONT DRIVE GEAR CYLINDRICAL ROLLER BEARING (for Front Transfer Case Side) 
      Fig 50: Removing The Bearing Rollers And Roller Cage
      GTY280958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the bearing rollers and roller cage.
      TEXT IN ILLUSTRATION

      *1 Roller
      *2 Roller Cage
      2. Fig 51: Removing The Drive Gear Bearing And Race
      GTY262622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the drive gear bearing and race from the front transfer case.
      3. Fig 52: Remove The Bearing
      GTY254988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the bearing from the front transfer case.
      • SST: 09649-17010 
      • SST: 09950-40011 
        1. 09951-04010
        2. 09952-04010
        3. 09953-04020
        4. 09954-04010
        5. 09955-04041
        6. 09957-04010
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
  44. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING (for Rear Transfer Case Side) 
      Fig 53: Removing The Snap Ring
      GTY265409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using needle-nose pliers, remove the snap ring from the rear transfer case.
      2. Fig 54: Identifying Transfer Case Bearing
      GTY133007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful of the straight pins when placing the case on the press.

    2. Using SST and a press, remove the bearing from the rear transfer case.
      • SST: 09950-60010 
        1. 09951-00540
        2. 09951-00650
        3. 09952-06010
      • SST: 09950-70010 
        1. 09951-07100
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