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Home >> Lexus >> 2016 >> LX 570 >> Repair and Diagnosis >> Transmission >> Transfer Case >> Transfer Case (Service Information) >> Transfer Assembly >> Disassembly [09/2015 - ] >> Procedure

Disassembly [09/2015 - ]: Procedure

  1. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY 
    1. Remove the bolt and bracket.
      GTY573156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE TRANSFER OIL PUMP PLATE 
    1. Remove the 4 bolts, oil pump plate and oil pump driven rotor.
      GTY599623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not drop the oil pump driven rotor.

    2. Remove the O-ring from the oil pump plate.
    3. Remove the transfer oil seal ring from the input shaft.
      GTY603356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the oil pump drive rotor from the input shaft.
      GTY680120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Oil Pump Drive Rotor
  3. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 2 straight pins.
      GTY553050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Case Straight Pin
      NOTE:

      Do not drop the straight pins.

  4. REMOVE TRANSFER CASE PLUG 
    1. Using a 10 mm hexagon wrench, remove the transfer case plug, compression spring, ball and relief valve seat.
      GTY577890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Case Plug
      *2 Compression Spring
      *3 Ball
      *4 Relief Valve Seat
  5. REMOVE TRANSFER OIL PUMP PLATE OIL SEAL 
    1. Using a screwdriver, pry out the oil seal from the oil pump plate.
      GTY132289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the oil seal and oil pump plate contact surfaces.

      HINT: 

      Tape the screwdriver tip before use.

  6. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using SST and a hammer, release the staked part of the companion flange lock nut.
      • SST: 09930-00010 
        1. 09931-00010
        2. 09931-00020
      GTY673901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be sure to use SST with the tapered surface facing the driven sprocket shaft.
      • Do not grind the tip of SST with a grinder, etc.
      • Completely loosen the staked part of the companion flange lock nut when removing it.
      • Do not damage the threads of the driven sprocket.
    2. Using SST to hold the front output shaft companion flange sub-assembly, remove the companion flange lock nut.
      • SST: 09330-00021 
      GTY560996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      * a Hold
      * b Turn
    3. Using SST, remove the front output shaft companion flange sub-assembly.
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04051
        6. 09957-04010
        7. 09958-04011
      GTY569216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      * a Hold
      * b Turn
    4. Remove the O-ring from the front output shaft companion flange sub-assembly.
  7. REMOVE TRANSFER OUTPUT SHAFT DUST DEFLECTOR 
    1. Using SST and a press, remove the transfer output shaft dust deflector.
      • SST: 09950-00020 
      • SST: 09950-60010 
        1. 09951-00340
        2. 09951-00470
        3. 09952-06010
      • SST: 09950-70010 
        1. 09951-07100
      GTY439715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not drop the front output shaft companion flange sub-assembly.

  8. REMOVE FRONT TRANSFER CASE OIL SEAL 

    See step  4

  9. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using SST and a hammer, release the staked part of the nut.
      • SST: 09930-00010 
        1. 09931-00010
        2. 09931-00020
      GTY136688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be sure to use SST with the tapered surface facing the shaft.
      • Do not grind the tip of SST with a grinder, etc.
      • Completely loosen the staked part of the nut when removing it.
      • Do not damage the threads of the rear transfer output shaft.
    2. Using SST to hold the companion flange, remove the lock nut.
      • SST: 09330-00021 
      GTY577326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      * a Hold
      * b Turn
    3. Using SST, remove the companion flange.
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04051
        6. 09957-04010
        7. 09958-04011
      GTY593475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      * a Hold
      * b Turn
    4. Remove the O-ring from the companion flange.
  10. REMOVE TRANSFER CASE REAR OIL SEAL 

    See step  3

  11. REMOVE NO. 1 TRANSFER CASE PLUG 
    1. Remove the No. 1 transfer case plug, compression spring and pin.
      GTY541102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Transfer Case Plug
      *2 Compression Spring
      *3 Pin
  12. REMOVE TRANSFER CASE PLUG 
    1. Using a 6 mm hexagon wrench, remove the plug.
      GTY611445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE REAR TRANSFER CASE ASSEMBLY 
    1. Remove the 14 bolts.
      GTY565266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear transfer case.

      HINT: 

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

  14. REMOVE FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING 
    1. Remove the needle roller bearing from the output shaft.
      GTY792525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Needle Roller Bearing
  15. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK 
    1. Using 2 screwdrivers and a hammer, tap off the 4 shift fork shaft snap rings.
      GTY109454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt. Then remove the No. 2 gear shift fork together with the high and low clutch sleeve from the shift actuator.
      GTY565267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY 
    1. Remove the No. 1 gear shift fork bolt.
      GTY565121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts.
      GTY611073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the transfer shift actuator assembly and No. 1 transfer gear shift fork from the rear transfer case.
      NOTE:

      Take care not to drop the No. 1 transfer gear shift fork.

      GTY554519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Shift Actuator Assembly
      *2 No. 1 Transfer Gear Shift Fork
    4. Remove the O-ring from the transfer shift actuator assembly.
      GTY235424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE REAR TRANSFER OUTPUT SHAFT ASSEMBLY 
    1. Using a snap ring expander, expand the snap ring as shown in the illustration.
      GTY564859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic-faced hammer, carefully tap the rear transfer case, and remove the output shaft together with the drive chain and driven sprocket.
      GTY122542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the output shaft and driven sprocket from the drive chain.
      NOTE:

      Do not drop the output shaft washers.

    4. Using a snap ring expander, remove the snap ring from the rear transfer case.
      GTY605092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FRONT DRIVE CLUTCH SLEEVE 
    GTY109424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the clutch sleeve from the output shaft.
  19. REMOVE SIDE GEAR SHAFT HOLDER BEARING 
    1. Using a screwdriver, remove the snap ring.
      GTY611137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the bearing.
      • SST: 09308-00010 
      GTY132664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Remove the 3 bolts and oil separator.
      GTY564856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the oil separator.
  21. REMOVE TRANSFER CASE MAGNET 
    GTY572569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the magnet from the oil separator.
  22. REMOVE TRANSFER INPUT SHAFT ASSEMBLY 
    1. Using a 14 mm hexagon wrench, remove the 2 case plugs from the front transfer case.
      GTY548001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, expand the snap ring as shown in the illustration. Then remove the input shaft from the front transfer case.
      GTY608769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    1. Using a screwdriver, remove the snap ring. Then remove the low planetary ring gear from the front transfer case.
      GTY244558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, remove the snap ring from the front transfer case.
      GTY611400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    1. Using a screwdriver, remove the snap ring. Then remove the bearing from the front transfer case.
      GTY564857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    1. Remove the seal ring from the input shaft.
      GTY564852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE TRANSFER INPUT SHAFT BEARING 
    1. Using a snap ring expander, remove the snap ring.
      GTY109476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press out the bearing.
      GTY124406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09555-55010 
      • SST: 09950-60010 
        1. 09951-00490
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

      Be careful not to drop or damage the input shaft, low planetary gear and low planetary gear bearings.

      HINT: 

      When the bearing is removed, the input shaft, low planetary gear, and 2 low planetary gear bearings will come off.

  27. REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH 
    1. Using SST, remove the bush.
      GTY109378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00041 
        1. 09387-01021
        2. 09387-01030
        3. 09387-01040
  28. REMOVE TRANSFER INPUT SHAFT PLUG 
    1. Using SST and a hammer, tap out the input shaft plug.
      GTY109477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-70010 
        1. 09951-07150
      • SST: 09950-60010 
        1. 09951-00300
  29. REMOVE TRANSFER OUTPUT SHAFT WASHER 
    1. Remove the 2 output shaft washers from the output shaft.
      GTY604658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER 
    1. Using 2 screwdrivers and a hammer, tap off the snap ring.
      GTY109482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the output shaft spacer from the output shaft.
      GTY130021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the seal ring from the output shaft spacer.
      GTY570629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the straight pin from the output shaft.
      GTY570630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE CENTER DIFFERENTIAL CASE 
    1. Remove the center differential case from the output shaft.
      GTY570628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the needle roller bearing.
      • SST: 09308-00010 
      GTY678347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the needle roller bearing.
      • SST: 09387-00041 
        1. 09387-01021
        2. 09387-01030
        3. 09387-01040
      GTY133149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TRANSFER OUTPUT SHAFT SPACER 
    1. Using 2 screwdrivers and a hammer, tap off the snap ring.
      GTY109486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the output shaft spacer from the output shaft.
      GTY130024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the straight pin from the output shaft.
      GTY604656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
    1. Remove the drive sprocket from the output shaft.
      GTY570621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TRANSFER DRIVE SPROCKET BEARING 
    1. Remove the bearing from the output shaft.
      GTY610785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE REAR TRANSFER OUTPUT SHAFT 
    1. Using SST and a press, press out the bearing.
      • SST: 09527-10011 
      GTY131735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to drop or damage the output shaft.

    2. Remove the needle roller bearing from the output shaft.
      GTY570619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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