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Transfer Assembly: Reassembly: Reassembly

  1. INSTALL TRANSFER FRONT DRIVE GEAR CYLINDRICAL ROLLER BEARING (for Rear Transfer Case Side) 
      Fig 1: Identifying Rear Transfer Case Bearing
      GTY144079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, install a new bearing to the rear transfer case.
      • SST: 09950-60020 
        • 09951-00710
      • SST: 09950-70010 
        • 09951-07100
      2. Fig 2: Identifying Snap Ring
      GTY129708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using needle-nose pliers, install the snap ring to the rear transfer case.
  2. INSTALL TRANSFER FRONT DRIVE GEAR BEARING 
      Fig 3: Identifying Drive Gear Bearing & Race
      GTY142056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the bearing and bearing race to the front transfer case.
  3. INSTALL TRANSFER FRONT DRIVE GEAR CYLINDRICAL ROLLER BEARING (for Front Transfer Case Side) 
      Fig 4: Identifying Transfer Case New Bearing (Outer Race)
      GTY126749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, install a new bearing (outer race) to the front transfer case.
      • SST: 09527-17011 
      • SST: 09951-01000 
      • SST: 09950-70010 
        • 09951-07150
  4. INSTALL TRANSFER FRONT CASE OIL SEAL 
      Fig 5: Identifying Oil Seal
      GTY138420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not tap in the oil seal at an angle.
      • Do not tap in the oil seal excessively.
    1. Using SST and a hammer, install a new oil seal to the front transfer case.
      • SST: 09223-15020 

      Standard depth

      1.0 to 1.5 mm (0.0394 to 0.0591 in.)

    2. Coat the lip of the outer shaft lever oil seal with MP grease.
  5. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
      Fig 6: Identifying Transfer Output Shaft Companion Flange Oil Seal
      GTY131636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not tap in the oil seal at an angle.
      • Do not tap in the oil seal excessively.
    1. Using SST and a hammer, install a new oil seal to the front transfer case.
      • SST: 09316-60011 
        • 09316-00011

      Standard depth

      2.5 to 3.0 mm (0.0984 to 0.118 in.)

    2. Coat the lip of the outer shaft lever oil seal with MP grease.
  6. INSTALL FORWARD CLUTCH DRAM OIL SEAL RING 
      Fig 7: Identifying Oil Seal Ring
      GTY127980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the oil seal ring to the sleeve.
  7. INSTALL TRANSFER COUNTER GEAR BEARING (for Front Transfer Case Side) 
      Fig 8: Identifying Front Transfer Case New Bearing (Outer Race)
      GTY122786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, install a new bearing (outer race) to the front transfer case.
      • SST: 09950-60010 
        • 09951-00580
        • 09951-00630
        • 09952-06010
      • SST: 09950-60020 
        • 09951-00750
        • 09951-00790
        • 09952-06010
      • SST: 09950-70010 
        • 09951-07100
  8. INSTALL TRANSFER COUNTER GEAR BEARING 
      Fig 9: Identifying Counter Gear New Bearing (Inner Race)
      GTY121129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. for Front Transfer Case Side:
      1. Using SST and a press, install a new bearing (inner race) to the counter gear.
        • SST: 09316-60011 
          • 09316-00011
          • 09613-22011
        • SST: 09950-60010 
          • 09951-00420

        HINT: 

        Disassemble SST (09613-22011) and only use the tube part.

      2. Fig 10: Identifying Counter Gear New Bearing (Inner Race)
      GTY127934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Rear Transfer Case Side:
      1. Using SST and a press, install a new bearing (inner race) to the counter gear.
        • SST: 09316-60011 
          • 09316-00011
        • SST: 09950-60010 
          • 09951-00420
  9. ADJUST COUNTER GEAR BEARING PRELOAD 
    1. Using a vernier caliper and precision straightedge, measure dimension A between the top surface of the front transfer case [*1] and the top surface of the counter gear bearing (outer race) [*2].
      Fig 11: Using Vernier Caliper & Precision Straightedge To Measure Dimension A
      GTY127358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Perform the measurement at 3 locations at intervals of 120° around the circumference of the outer race and calculate the average.

      NOTE:

      Perform the measurements with the idler gear assembly removed.

    2. Using a vernier caliper and precision straightedge, measure dimension B between the top surface of the rear transfer case [*1] and the surface which contacts the transfer counter gear shim [*2].
      Fig 12: Using Vernier Caliper & Precision Straightedge To Measure Dimension B
      GTY123615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not add the thickness of the precision straightedge.

    3. Using the formula below, calculate the thickness of the transfer counter gear shim and select an appropriate shim from the table.

      Transfer counter gear shim thickness

      Dimension B - Dimension A

      Transfer Counter Gear Shim Thickness

      Mark Specified Condition Mark Specified Condition Mark Specified Condition
      40 1.39 to 1.41 mm (0.0548 to 0.0555 in) 72 1.71 to 1.73 mm (0.0673 to 0.0681 in) 04 2.03 to 2.05 mm (0.0799 to 0.0807 in)
      42 1.41 to 1.43 mm (0.0555 to 0.0562 in) 74 1.73 to 1.75 mm (0.0681 to 0.0688 in) 06 2.05 to 2.07 mm (0.0807 to 0.0814 in)
      44 1.43 to 1.45 mm (0.0562 to 0.0570 in) 76 1.75 to 1.77 mm (0.0688 to 0.0696 in) 08 2.07 to 2.09 mm (0.0814 to 0.0822 in)
      46 1.45 to 1.47 mm (0.0570 to 0.0578 in) 78 1.77 to 1.79 mm (0.0696 to 0.0704 in) 10 2.09 to 2.11 mm (0.0822 to 0.0830 in)
      48 1.47 to 1.49 mm (0.0578 to 0.0586 in) 80 1.79 to 1.81 mm (0.0704 to 0.0712 in) 12 2.11 to 2.13 mm (0.0830 to 0.0838 in)
      50 1.49 to 1.51 mm (0.0586 to 0.0594 in) 82 1.81 to 1.83 mm (0.0712 to 0.0720 in) 14 2.13 to 2.15 mm (0.0838 to 0.0846 in)
      52 1.51 to 1.53 mm (0.0594 to 0.0602 in) 84 1.83 to 1.85 mm (0.0720 to 0.0728 in) 16 2.15 to 2.17 mm (0.0846 to 0.0854 in)
      54 1.53 to 1.55 mm (0.0602 to 0.0610 in) 86 1.85 to 1.87 mm (0.0728 to 0.0736 in) 18 2.17 to 2.19 mm (0.0854 to 0.0862 in)
      56 1.55 to 1.57 mm (0.0610 to 0.0618 in) 88 1.87 to 1.89 mm (0.0736 to 0.0744 in) 20 2.19 to 2.21 mm (0.0862 to 0.0870 in)
      58 1.57 to 1.59 mm (0.0618 to 0.0625 in) 90 1.89 to 1.91 mm (0.0744 to 0.0751 in) 22 2.21 to 2.23 mm (0.0870 to 0.0877 in)
      60 1.59 to 1.61 mm (0.0625 to 0.0633 in) 92 1.91 to 1.93 mm (0.0751 to 0.0759 in) 24 2.23 to 2.25 mm (0.0877 to 0.0885 in)
      62 1.61 to 1.63 mm (0.0633 to 0.0641 in) 94 1.93 to 1.95 mm (0.0759 to 0.0767 in) 26 2.25 to 2.27 mm (0.0885 to 0.0893 in)
      64 1.63 to 1.65 mm (0.0641 to 0.0649 in) 96 1.95 to 1.97 mm (0.0767 to 0.0775 in) 28 2.27 to 2.29 mm (0.0893 to 0.0901 in)
      66 1.65 to 1.67 mm (0.0649 to 0.0657 in) 98 1.97 to 1.99 mm (0.0775 to 0.0783 in) 30 2.29 to 2.31 mm (0.0901 to 0.0909 in)
      68 1.67 to 1.69 mm (0.0657 to 0.0665 in) 00 1.99 to 2.01 mm (0.0783 to 0.0791 in) - -
      70 1.69 to 1.71 mm (0.0665 to 0.0673 in) 02 2.01 to 2.03 mm (0.0791 to 0.0799 in) - -
      4. Fig 13: Identifying Rear Transfer Case New Bearing (Outer Race)
      GTY127047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST and a press, install the shim and a new bearing (outer race) to the rear transfer case.
      • SST: 09950-60020 
        • 09951-00750
      • SST: 09950-70010 
        • 09951-07100
      5. Fig 14: Identifying Front Transfer Case Counter Gear
      GTY135283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the counter gear to the front transfer case.
      6. Fig 15: Identifying Rear Transfer Case Bolts
      GTY127696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the rear transfer case with the 7 bolts to the front transfer case.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      7. Fig 16: Using SST To Hold Companion Flange
      GTY121806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the companion flange to the transfer assembly, and then using SST, hold the companion flange in place.
      • SST: 09213-58013 
      • 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.

      8. Fig 17: Tightening Companion Flange Bolt
      GTY142410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Tighten the companion flange bolt.

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

    9. Remove SST and turn the counter gear back and forth to settle the bearing.
      10. Fig 18: Measuring Turning Torque Of Counter Gear Bearing (Counter Gear Preload) Using Torque Wrench
      GTY123187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Perform the measurements with the idler gear assembly removed.

    10. Using a torque wrench, measure the turning torque of the counter gear bearing (counter gear preload).

      Standard turning torque

      0.66 to 1.18 N*m (6.7 to 12.0 kgf*cm, 5.8 to 10.4 in.*lbf)

      HINT: 

      Measure the turning torque while turning the counter gear at 60 rpm (1 rotation per second).

      • If the turning torque is not as specified, replace the counter gear shim with one of a different thickness so that the measured value is within the standard range.
      11. Fig 19: Using SST To Hold Companion Flange
      GTY121806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Using SST, hold the companion flange in place.
      • SST: 09213-58013 
      • 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.

      12. Fig 20: Identifying Companion Flange & Bolt
      GTY127627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Remove the companion flange bolt and companion flange from the transfer assembly.
      13. Fig 21: Identifying Rear Transfer Case Bolts
      GTY127696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Remove the 7 bolts from the rear transfer case.
    14. Remove the counter gear.
  10. INSTALL TRANSFER OIL PUMP PLATE SUB-ASSEMBLY 
    1. Install the drive rotor and driven rotor to the front transfer case.
    2. Install the plate pin to the oil pump plate.
    3. Install the plate to the front transfer case.
  11. INSTALL TRANSFER IDLER GEAR BEARING (for Front Transfer Case Side) 
      Fig 22: Identifying Front Transfer Case New Bearing (Outer Race)
      GTY125059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, install a new bearing (outer race) to the front transfer case.
      • SST: 09950-60020 
        • 09951-00890
      • SST: 09950-70010 
        • 09951-07100
  12. INSTALL TRANSFER IDLER GEAR BEARING 
      Fig 23: Identifying Idler Gear New Bearing (Inner Race)
      GTY128724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. for Front Transfer Case Side:

      Using SST and a press, install a new bearing (inner race) to the idler gear.

      • SST: 09554-22010 
      2. Fig 24: Identifying Idler Gear New Bearing (Inner Race)
      GTY130152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Rear Transfer Case Side:

      Using SST and a press, install a new bearing (inner race) to the idler gear.

      • SST: 09950-60010 
        • 09951-00540
      • SST: 09554-22010 
  13. ADJUST TRANSFER IDLER GEAR BEARING PRELOAD 
      Fig 25: Identifying Front Transfer Case Counter Gear
      GTY135283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the counter gear to the front transfer case.
      2. Fig 26: Identifying Idler Gear
      GTY127625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the idler gear to the front transfer case.
    3. Using a vernier caliper and precision straightedge, measure dimension A between the top surface of the front transfer case [*1] and the top surface of the idler gear bearing (outer race) [*2].
      Fig 27: Using Vernier Caliper & Precision Straightedge To Measure Dimension A
      GTY143839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Perform the measurement at 3 locations at intervals of 120° around the circumference of the outer race and calculate the average.

    4. Using a vernier caliper and precision straightedge, measure dimension B between the top surface of the rear transfer case [*1] and the surface which contacts the transfer idler gear shim [*2].
      Fig 28: Using Vernier Caliper & Precision Straightedge To Measure Dimension B
      GTY132305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not add the thickness of the precision straightedge.

    5. Using the formula below, calculate the thickness of the transfer idler gear shim and select an appropriate shim from the table.

      Transfer idler gear shim thickness

      Dimension B - Dimension A

      Transfer Idler Gear Shim Thickness

      Mark Specified Condition Mark Specified Condition Mark Specified Condition
      90 0.89 to 0.91 mm (0.0350 to 0.0358 in) 22 1.21 to 1.23 mm (0.0476 to 0.0484 in) 54 1.53 to 1.55 mm (0.0602 to 0.0610 in)
      92 0.91 to 0.93 mm (0.0358 to 0.0366 in) 24 1.23 to 1.25 mm (0.0484 to 0.0492 in) 56 1.55 to 1.57 mm (0.0610 to 0.0618 in)
      94 0.93 to 0.95 mm (0.0366 to 0.0374 in) 26 1.25 to 1.27 mm (0.0492 to 0.0499 in) 58 1.57 to 1.59 mm (0.0618 to 0.0625 in)
      96 0.95 to 0.97 mm (0.0374 to 0.0381 in) 28 1.27 to 1.29 mm (0.0499 to 0.0507 in) 60 1.59 to 1.61 mm (0.0625 to 0.0633 in)
      98 0.97 to 0.99 mm (0.0381 to 0.0389 in) 30 1.29 to 1.31 mm (0.0507 to 0.0515 in) 62 1.61 to 1.63 mm (0.0633 to 0.0641 in)
      00 0.99 to 1.01 mm (0.0389 to 0.0397 in) 32 1.31 to 1.33 mm (0.0515 to 0.0523 in) 64 1.63 to 1.65 mm (0.0641 to 0.0649 in)
      02 1.01 to 1.03 mm (0.0397 to 0.0405 in) 34 1.33 to 1.35 mm (0.0523 to 0.0531 in) 66 1.65 to 1.67 mm (0.0649 to 0.0657 in)
      04 1.03 to 1.05 mm (0.0405 to 0.0413 in) 36 1.35 to 1.37 mm (0.0531 to 0.0539 in) 68 1.67 to 1.69 mm (0.0657 to 0.0665 in)
      06 1.05 to 1.07 mm (0.0413 to 0.0421 in) 38 1.37 to 1.39 mm (0.0539 to 0.0547 in) 70 1.69 to 1.71 mm (0.0665 to 0.0673 in)
      08 1.07 to 1.09 mm (0.0421 to 0.0429 in) 40 1.39 to 1.41 mm (0.0547 to 0.0555 in) 72 1.71 to 1.73 mm (0.0673 to 0.0681 in)
      10 1.09 to 1.11 mm (0.0429 to 0.0437 in) 42 1.41 to 1.43 mm (0.0555 to 0.0562 in) 74 1.73 to 1.75 mm (0.0681 to 0.0688 in)
      12 1.11 to 1.13 mm (0.0437 to 0.0444 in) 44 1.43 to 1.45 mm (0.0562 to 0.0570 in) 76 1.75 to 1.77 mm (0.0688 to 0.0696 in)
      14 1.13 to 1.15 mm (0.0444 to 0.0452 in) 46 1.45 to 1.47 mm (0.0570 to 0.0578 in) 78 1.77 to 1.79 mm (0.0696 to 0.0704 in)
      16 1.15 to 1.17 mm (0.0452 to 0.0460 in) 48 1.47 to 1.49 mm (0.0578 to 0.0586 in) 80 1.79 to 1.81 mm (0.0704 to 0.0712 in)
      18 1.17 to 1.19 mm (0.0460 to 0.0468 in) 50 1.49 to 1.51 mm (0.0586 to 0.0594 in) - -
      20 1.19 to 1.21 mm (0.0468 to 0.0476 in) 52 1.51 to 1.53 mm (0.0594 to 0.0602 in) - -
      6. Fig 29: Identifying Rear Transfer Case) Shim & New Bearing (Outer Race)
      GTY143031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST and a press, install the shim and a new bearing (outer race) to the rear transfer case.
      • SST: 09950-60020 
        • 09951-00780
        • 09951-00890
        • 09952-06010
      • SST: 09950-70010 
        • 09951-07100
      7. Fig 30: Identifying Rear Transfer Case Bolts
      GTY127696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the rear transfer case with the 7 bolts to the front transfer case.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      8. Fig 31: Using SST To Hold Companion Flange
      GTY121806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the companion flange to the transfer assembly, and then using SST, hold the companion flange in place.
      • SST: 09213-58013 
      • 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.

      9. Fig 32: Tightening Companion Flange Bolt
      GTY142410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Tighten the companion flange bolt.

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

    10. Remove SST and turn the idler gear back and forth to settle the bearing.
      11. Fig 33: Measuring Turning Torque Of Idler Gear Bearing (Idler Gear Preload) Using Torque Wrench
      GTY141672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      The measured turning torque for the idler gear preload is the combined preload of the idler gear and counter gear.

    11. Using a torque wrench, measure the turning torque of the idler gear bearing (idler gear preload).

      Standard turning torque

      1.54 to 2.64 N*m (15.7 to 26.9 kgf*cm, 13.6 to 23.4 in.*lbf)

      HINT: 

      Measure the turning torque while turning the counter gear at 60 rpm (1 rotation per second).

      • If the turning torque is not as specified, replace the idler gear shim with one of a different thickness so that the measured value is within the standard range.
      12. Fig 34: Using SST To Hold Companion Flange
      GTY121806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Using SST, hold the companion flange in place.
      • SST: 09213-58013 
      • 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.

      13. Fig 35: Identifying Companion Flange & Bolt
      GTY127627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Remove the companion flange bolt and companion flange form the transfer assembly.
    14. Remove the 7 bolts and rear transfer case from the front transfer case.
    15. Remove the idler gear and counter gear from the front transfer case.
  14. INSTALL TRANSFER OIL COOLER RELIEF VALVE 
      Fig 36: Identifying Relief Valve
      GTY123621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the relief valve to the front transfer case.
      2. Fig 37: Installing The Compression Spring And Valve Plate
      GTY124040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    2. Install the compression spring and valve plate to the front transfer case with the bolt.

      Torque: 6.7 N*m (68 kgf*cm, 59 in.*lbf) 

  15. INSTALL NO. 1 TRANSFER OIL STRAINER 
      Fig 38: Identifying Oil Strainer
      GTY124197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the oil strainer to the front transfer case.
  16. INSTALL TRANSFER OIL SEPARATOR 
      Fig 39: Identifying Oil Separator Bolts
      GTY124332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the oil separator with the 3 bolts.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

  17. INSTALL DRIVE PINION COMPANION FLANGE OIL SEAL 
      Fig 40: Using SST & Hammer To Install New Oil Seal To Companion Flange
      GTY128825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not tap in the oil seal at an angle.
      • Do not tap in the oil seal excessively.
    1. Using SST and a hammer, install a new oil seal to the companion flange.
      • SST: 09950-60010 
        • 09951-00420
      • SST: 09950-70010 
        • 09951-07100

      Standard oil seal depth

      0 to 0.3 mm (0 to 0.0118 in.)

    2. Coat the lip of the outer shaft lever oil seal with MP grease.
  18. INSTALL TRANSFER OIL SEAL RING 
      Fig 41: Identifying Oil Seal Ring
      GTY135965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not excessively widen the oil seal ring.

    1. Install the oil seal ring to the input shaft.
  19. INSTALL TRANSFER INPUT SHAFT 
      Fig 42: Identifying Transfer Input Shaft
      GTY143626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the input shaft to the drive gear.
  20. INSTALL TRANSFER FRONT DRIVE GEAR PIN 
      Fig 43: Identifying Front Transfer Case Drive Gear Pin
      GTY132170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the pin to the front transfer case.
  21. INSTALL TRANSFER FRONT DRIVE GEAR ASSEMBLY 
      Fig 44: Identifying Front Transfer Case Drive Gear
      GTY132313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the drive gear and input shaft to the front transfer case.
  22. INSTALL TRANSFER COUNTER GEAR ASSEMBLY 
      Fig 45: Identifying Front Transfer Case Counter Gear
      GTY135283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the counter gear to the front transfer case.
  23. INSTALL TRANSFER OIL PUMP DRIVE SHAFT 
      Fig 46: Identifying Front Transfer Case Oil Pump Drive Shaft
      GTY130554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the drive shaft to the front transfer case.
  24. INSTALL TRANSFER IDLER GEAR ASSEMBLY 
      Fig 47: Identifying Front Transfer Case Idler Gear
      GTY129601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the idler gear to the front transfer case.
  25. INSTALL REAR TRANSFER CASE 
      Fig 48: Applying Seal Packing To Transfer Case
      GTY123627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surfaces.
      • Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG material) must be removed and reapplied.
    1. 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

      Seal packing diameter

      1.2 mm (0.0472 in.)

      2. Fig 49: Identifying Rear Transfer Case Bolts
      GTY129444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear transfer case with the 7 bolts to the front transfer case.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

  26. INSTALL TRANSFER INPUT GEAR STOPPER 
      Fig 50: Identifying Transfer Input Gear Stopper
      GTY129928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the gear stopper to the input shaft.
  27. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
      Fig 51: Identifying Transfer Input Gear Stopper Shaft Snap Ring
      GTY129842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, install the snap ring to the input shaft.
  28. INSTALL BREATHER OIL DEFLECTOR 
      Fig 52: Identifying Oil Deflector Bolts
      GTY128936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the oil deflector with the 2 bolts to the rear transfer case.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

  29. INSTALL TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING 
      Fig 53: Identifying Differential Case New Bearing (Inner Race)
      GTY121910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, install a new bearing (inner race) to the differential case.
      • SST: 09316-60011 
        • 09316-00011
        • 09316-00021
  30. INSTALL NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY 
    1. Install the differential case to the rear transfer case.
  31. INSTALL TRANSFER OUTPUT SHAFT SHIM 
      Fig 54: Identifying Output Shaft Shim
      GTY130355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the output shaft shim to the differential case.
  32. INSTALL NO. 2 TRANSFER THRUST BEARING RACE 
      Fig 55: Identifying No. 2 Transfer Thrust Bearing Race
      GTY129266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the bearing race to the output shaft shim.
  33. INSTALL DIFFERENTIAL CASE NEEDLE ROLLER BEARING 
      Fig 56: Identifying Needle Roller Bearing
      GTY129254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the needle roller bearing to the bearing race.
  34. INSTALL TRANSFER OUTPUT SHAFT WASHER 
      Fig 57: Identifying Shaft Washers
      GTY128197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 2 shaft washers to the differential case.
  35. INSTALL NO. 1 TRANSFER THRUST BEARING RACE 
      Fig 58: Identifying No. 1 Transfer Thrust Bearing Race
      GTY123622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the bearing race to the needle roller bearing.
  36. ADJUST TRANSFER OUTPUT SHAFT SHIM 
    1. Using a vernier caliper and precision straightedge, measure dimension A between the top surface of the extension housing [*1] and the surface which contacts the No. 1 thrust bearing race [*2].
      Fig 59: Using Vernier Caliper & Precision Straightedge To Measure Dimension A
      GTY136871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not add the thickness of the precision straightedge.

    2. Using a vernier caliper and precision straightedge, measure dimension B between the surface of the No. 1 thrust bearing race [*1] and the surface of the rear transfer case extension housing [*2].
      Fig 60: Using Vernier Caliper & Precision Straightedge To Measure Dimension B
      GTY124622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not add the thickness of the precision straightedge.

    3. Using the formula below, calculate the thickness of the transfer output shim and select an appropriate shim from the table.

      Transfer output shim thickness

      Dimension A - Dimension B

      Transfer Output Shim Thickness

      Mark Specified Condition Mark Specified Condition
      98 0.96 to 1.00 mm (0.0378 to 0.0393 in.) 43 1.41 to 1.45 mm (0.0556 to 0.0570 in.)
      03 1.01 to 1.05 mm (0.0398 to 0.0413 in.) 48 1.46 to 1.50 mm (0.0575 to 0.0590 in.)
      08 1.06 to 1.10 mm (0.0418 to 0.0433 in.) 53 1.51 to 1.55 mm (0.0959 to 0.0610 in.)
      13 1.11 to 1.15 mm (0.0437 to 0.0452 in.) 58 1.56 to 1.60 mm (0.0615 to 0.0629 in.)
      18 1.16 to 1.20 mm (0.0457 to 0.0472 in.) 63 1.61 to 1.65 mm (0.0634 to 0.0649 in.)
      23 1.21 to 1.25 mm (0.0477 to 0.0492 in.) 68 1.66 to 1.70 mm (0.0653 to 0.0669 in)
      28 1.26 to 1.30 mm (0.0496 to 0.0511 in.) 73 1.71 to 1.75 mm (0.0674 to 0.0688 in.)
      33 1.31 to 1.35 mm (0.0516 to 0.0532 in.) 78 1.76 to 1.80 mm (0.0693 to 0.0708 in.)
      38 1.36 to 1.40 mm (0.0536 to 0.0551 in.) - -
  37. INSTALL TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING 
      Fig 61: Using SST & Press To Install New Bearing (Outer Race) To Extension Housing
      GTY133460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, install a new bearing (outer race) to the extension housing.
      • SST: 09950-60010 
        • 09951-00600
      • SST: 09950-70010 
        • 09951-07100
  38. INSTALL NO. 1 DIFFERENTIAL CASE HOLE SNAP RING 
      Fig 62: Using Needle-Nose Pliers To Install Snap Ring To Extension Housing
      GTY141675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using needle-nose pliers, install the snap ring to the extension housing.
  39. INSTALL TRANSFER EXTENSION HOUSING OIL SEAL 
      Fig 63: Using SST & Hammer To Install New Oil Seal To Extension Housing
      GTY127465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not tap in the oil seal at an angle.
      • Do not tap in the oil seal excessively.
      • Be careful of the positions of the straight pins when performing this procedure.
    1. Using SST and a hammer, install a new oil seal to the extension housing.
      • SST: 09726-36010 
      • SST: 09950-70010 
        • 09951-07100

      Standard oil seal depth

      12 to 12.5 mm (0.473 to 0.492 in.)

    2. Coat the lip of the outer shaft lever oil seal with MP grease.
  40. INSTALL TRANSFER EXTENSION HOUSING 
      Fig 64: Apply Seal Packing To Transfer Extension Housing
      GTY123625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any oil from the contact surfaces.
      • Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG material) must be removed and reapplied.
    1. Apply seal packing to the transfer extension housing as shown in the illustration.

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Seal packing diameter

      1.2 mm (0.0472 in.)

      2. Fig 65: Identifying Transfer Extension Housing Bolts
      GTY135640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transfer extension housing with the 11 bolts to the rear transfer case.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

  41. INSTALL DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY 
    1. Install the companion flange to the output shaft.
    2. Install a new nut to the output shaft.
      3. Fig 66: Tightening Transfer Output Shaft Nut
      GTY149308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, hold the companion flange in place.
      • SST: 09330-00021 
      • SST: 09950-30012 
        • 09955-03040
    4. Using a 30 mm socket wrench, tighten the transfer output shaft nut.

      Torque: 142 N*m (1448 kgf*cm, 105 ft.*lbf) 

      5. Fig 67: Using Chisel & Hammer To Stake Transfer Output Shaft Nut
      GTY126221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a chisel and hammer, stake the transfer output shaft nut.
  42. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
      Fig 68: Using SST To Hold Companion Flange
      GTY121806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the companion flange to the transfer assembly, and then using SST, hold the companion flange in place.
      • SST: 09213-58013 
      • 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 69: Tightening Companion Flange Bolt
      GTY142410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the companion flange bolt.

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

  43. INSTALL NO. 2 TRANSFER CASE PLUG 
      Fig 70: Using Straight Hexagon Wrench To Remove Case Plug & Gasket
      GTY140802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 17 mm straight hexagon wrench, install a new gasket and the case plug to the rear transfer case.

      Torque: 98 N*m (1000 kgf*cm, 72 ft.*lbf) 

  44. INSTALL TRANSFER CASE BREATHER PLUG 
      Fig 71: Identifying Transfer Case Breather Plug
      GTY132038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a hammer, install the breather plug to the front transfer case.
      • SST: 09350-30020 
        • 09350-07110
  45. INSTALL TRANSFER DRAIN PLUG 
      Fig 72: Identifying Plug
      GTY128687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 10 mm hexagon socket wrench, install a new gasket and the drain plug to the rear transfer case.

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

  46. INSTALL FILLER PLUG 
      Fig 73: Identifying Plug
      GTY142358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 10 mm hexagon socket wrench, install a new gasket and the filler plug to the rear transfer case.

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

  47. INSTALL TRANSFER CASE PLUG 
      Fig 74: Identifying Plug
      GTY143935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 6 mm hexagon socket wrench, install 2 new O-rings and the 2 case plugs to the front transfer case.

      Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) 

  48. INSTALL DYNAMIC DAMPER 
      Fig 75: Identifying Rear Transfer Case
      GTY140596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the damper and 2 washers with the bolt to the rear transfer case.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

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