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Reassembly [08/2015 - ]: Procedure

  1. INSTALL TRANSFER LOW PLANETARY RING GEAR 
    1. Install the low planetary ring gear to the front transfer case.
    2. Using a screwdriver, install the snap ring.
      GTY632116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL PIN 
    1. Install the pin.
      GTY247625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL COMPRESSION SPRING 
    1. Install the spring.
  4. INSTALL TRANSFER CASE PLUG 
    1. Install the transfer case plug.

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

  5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER 
    1. Install the washer.
      GTY224037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL TRANSFER DRIVE SPROCKET BEARING 
    1. Install the bearing.
  7. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
    1. Install the transfer drive sprocket.
  8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER 
    1. Install the output shaft spacer.
  9. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING 
    1. Using SST and a press, install a new bearing.
      GTY669075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-60011 
        1. 09316-00011
        2. 09316-00071
      TEXT IN ILLUSTRATION

      *1 Groove
      Rear
      NOTE:

      Install the bearing so that the bearing snap ring groove faces the rear.

  10. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER 
    1. Install the washer.
      GTY224071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
    1. Install the needle roller bearing.
  12. INSTALL TRANSFER CLUTCH HUB 
    1. Install the transfer clutch hub.
  13. INSTALL CENTER DIFFERENTIAL CASE 
    1. Install the center differential case.
      GTY247637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL 
    1. Install the ball.
  15. INSTALL NO. 2 TRANSFER OUTPUT SHAFT SPACER 
    1. Install the spacer.
    2. Using a snap ring expander, install the snap ring.
  16. INSPECT DRIVE SPROCKET RADIAL CLEARANCE 
    GTY222742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a dial indicator, measure the radial clearance of the drive sprocket.

      Standard clearance

      0.01 to 0.06 mm (0.000394 to 0.00236 in.)

      Maximum clearance

      0.06 mm (0.00236 in.)

      If the clearance is more than the maximum, replace the drive sprocket, rear output shaft or bearing.

  17. INSPECT DRIVE SPROCKET THRUST CLEARANCE 
    GTY247636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a feeler gauge, measure the thrust clearance of the drive sprocket.

      Standard clearance

      0.15 to 0.24 mm (0.00591 to 0.00944 in.)

      Maximum clearance

      0.24 mm (0.00944 in.)

      If the clearance is more than the maximum, replace the drive sprocket.

  18. INSTALL TRANSFER INPUT SHAFT BEARING 
    1. Using SST and a press, install a new bearing with the groove facing forward.
      GTY621829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-15020 
      • SST: 09515-30010 
      • SST: 09950-70010 
        1. 09951-07100
  19. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING 
    GTY134081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Select a new snap ring that allows minimal axial 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 (0.0591 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.
  20. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, install the low planetary gear spline piece and snap ring.
      GTY685769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    GTY612347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, press in a new low planetary gear bearing.
      • SST: 09950-60010 
        1. 09951-00570
      • SST: 09950-70010 
        1. 09951-07100

      Press in depth

      7.7 to 8.3 mm (0.304 to 0.326 in.)

  22. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    1. Apply gear oil to 2 new seal rings.
      GTY229411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 seal rings to the input shaft.
      NOTE:

      When installing the seal ring, make sure not to expand it so that its inner diameter exceeds 65 mm (2.56 in.).

  23. INSTALL TRANSFER LOW PLANETARY GEAR THRUST BEARING 
    1. Install the bearing.
      GTY231192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Front
  24. INSTALL NO. 1 TRANSFER THRUST BEARING RACE 
    1. Install the thrust bearing race.
  25. INSTALL TRANSFER INPUT SHAFT 
    1. Install the transfer input shaft.
  26. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER 
    1. Install the washer.
      GTY154631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL TRANSFER INPUT GEAR STOPPER BALL 
    1. Install the ball.
  28. INSTALL TRANSFER INPUT GEAR STOPPER 
    1. Install the input gear stopper.
  29. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    1. Select a new input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.00197 to 0.00590 in.) of axial play.
      GTY154654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Snap Ring Thickness

      Specified Condition
      2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      2.15 to 2.20 mm (0.0846 to 0.0866 in.)
      2.20 to 2.25 mm (0.0866 to 0.0886 in.)
      2.25 to 2.30 mm (0.0886 to 0.0906 in.)
      2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      2.35 to 2.40 mm (0.0925 to 0.0945 in.)
      2.40 to 2.45 mm (0.0945 to 0.0965 in.)
      2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      2.50 to 2.55 mm (0.0984 to 0.100 in.)
      2.55 to 2.60 mm (0.100 to 0.102 in.)
      2.60 to 2.65 mm (0.102 to 0.104 in.)
      2.65 to 2.70 mm (0.104 to 0.106 in.)
      2.70 to 2.75 mm (0.106 to 0.108 in.)
      2.75 to 2.80 mm (0.108 to 0.110 in.)
      2.80 to 2.85 mm (0.110 to 0.112 in.)
      2.85 to 2.90 mm (0.112 to 0.114 in.)
      2.90 to 2.95 mm (0.114 to 0.116 in.)
      2.95 to 3.00 mm (0.116 to 0.118 in.)
      3.00 to 3.05 mm (0.118 to 0.120 in.)
    2. Using a snap ring expander, install the snap ring.
      GTY136731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT SUB-ASSEMBLY 
    1. Install the low planetary gear together with the input shaft.
      GTY154630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install the shaft snap ring.
      GTY676821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL TRANSFER OIL PUMP GEAR 
    1. Install the transfer oil pump gear.
      GTY285523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL TRANSFER OIL PUMP BODY O-RING 
    1. Coat a new O-ring with gear oil and install it to the oil pump body.
      GTY671089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Install the oil pump body with the 3 bolts.
      GTY628201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  34. INSTALL TRANSFER CASE MAGNET 
  35. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Install the oil separator with the 3 bolts.
      GTY289796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  36. INSTALL FILLER PLUG 
    1. Install a new gasket and the filler plug.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

  37. INSTALL DRAIN PLUG 
    1. Install a new gasket and the drain plug.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

  38. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY 
    1. Install a new O-ring to the transfer shift actuator assembly.
      GTY684774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transfer shift actuator assembly with the 3 bolts.
      GTY628200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    3. Using a screwdriver and hammer, tap on the 2 snap rings.
  39. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING 
    1. Using SST and a press, install a new input gear radial ball bearing.
      GTY255036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-60011 
        1. 09316-00031
  40. INSTALL TRANSFER DRIVEN SPROCKET BEARING 
    1. Using SST and a press, install a new driven sprocket bearing.
      GTY676778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-60011 
        1. 09316-00071
  41. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY 
    1. Install the rear output shaft and driven sprocket to the front drive chain.
      GTY247632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear output shaft, front drive chain and driven sprocket to the rear transfer case.
      GTY134097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Check that the rear output shaft and driven sprocket turn without much effort.

    3. Using a snap ring expander, install the snap ring.
      NOTE:

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

  42. INSTALL CENTER DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE 
    1. Install the center differential lock fork and front drive clutch sleeve.
      GTY631880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Front
      NOTE:

      Install the clutch sleeve in the correct direction.

    2. Install the bolt.

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

    3. Using a screwdriver and hammer, drive in the snap ring.
  43. INSTALL NO. 2 TRANSFER GEAR SHIFT FORK SUB-ASSEMBLY WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE 
    1. Install the No. 2 gear shift fork and high and low clutch sleeve.
      GTY654371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Front
      NOTE:

      Install the clutch sleeve in the correct direction.

    2. Install the bolt.

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

  44. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
    1. Install the needle roller bearing to the input shaft.
  45. INSTALL TRANSFER OUTPUT SHAFT SPACER 
    1. Install the transfer output shaft spacer to the input shaft.
  46. INSTALL REAR TRANSFER CASE 
    1. Apply seal packing to the rear transfer case as shown in the illustration.
      GTY624683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      TEXT IN ILLUSTRATION

      *1 Seal Packing
      NOTE:

      If the removed rear transfer case is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the rear transfer case contact surface, 2) clean off any remaining old seal packing from the rear transfer case contact surface, and 3) reapply seal packing to the rear transfer case.

    2. Install the clamp and rear transfer case with the 12 bolts.
      GTY642512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

      NOTE:

      Tighten the bolts of the rear transfer case within 10 minutes of applying the seal packing. The seal packing will dry very quickly.

  47. INSTALL COLLAR 
    1. Install the collar.
      GTY234943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL TRANSFER OUTPUT SHAFT WASHER 
    1. Install the 2 washers.
  49. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Apply seal packing to the extension housing as shown in the illustration.
      GTY616996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      TEXT IN ILLUSTRATION

      *1 Seal Packing
      NOTE:

      If the removed extension housing is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the housing contact surface, 2) clean off any remaining old seal packing from the housing 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.
      GTY628243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 12 N*m (122 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.

  50. INSTALL TRANSFER CASE REAR OIL SEAL 

    See step  6

  51. INSTALL REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal.
      GTY650949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00320
      • SST: 09950-70010 
        1. 09951-07100
    2. Coat the lip of the oil seal with MP grease.
  52. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Apply gear oil to the connecting areas of the companion flange and output shaft.
      GTY234336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the companion flange to the output shaft.
      TEXT IN ILLUSTRATION

      Rear
    3. Using SST to hold the companion flange, install a new lock nut.
      • SST: 09330-00021 

      Torque: 118 N*m (1203 kgf*cm, 87 ft.*lbf) 

    4. Using a chisel and hammer, stake the lock nut.
      GTY377733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a CORRECT
      *b INCORRECT
      NOTE:
      • Securely stake the shaft to the lock nut groove.
      • Be careful not to damage the parts around the lock nut.
      • Do not apply excessive force to the shaft.
  53. INSTALL TRANSFER CASE FRONT OIL SEAL 

    See step  6

  54. INSTALL FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal.
      GTY650952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00320
      • SST: 09950-70010 
        1. 09951-07100
    2. Coat the lip of the oil seal with MP grease.
  55. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    GTY285742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Apply gear oil to the connecting areas of the companion flange and driven sprocket.
    2. Install the companion flange to the driven sprocket.
      TEXT IN ILLUSTRATION

      Front
    3. Using SST to hold the companion flange, install a new lock nut.
      • SST: 09330-00021 

      Torque: 118 N*m (1203 kgf*cm, 87 ft.*lbf) 

    4. Using a chisel and hammer, stake the lock nut.
      GTY377733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a CORRECT
      *b INCORRECT
      NOTE:
      • Securely stake the shaft to the lock nut groove.
      • Be careful not to damage the parts around the lock nut.
      • Do not apply excessive force to the shaft.
  56. INSTALL BREATHER OIL DEFLECTOR 
    1. Install the oil deflector.
  57. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Install the case cover with the 4 bolts.
      GTY675961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

  58. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the retainer upper surface.
      GTY643462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00590
      • SST: 09950-70010 
        1. 09951-07100
    2. Coat the lip of the oil seal with MP grease.
  59. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY 
    1. Apply seal packing to the bearing retainer as shown in the illustration.
      GTY647130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      TEXT IN ILLUSTRATION

      *1 Seal Packing
      NOTE:

      If the removed bearing retainer is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the retainer contact surface, 2) clean off any remaining old seal packing from the retainer contact surface, and 3) reapply seal packing to the retainer.

    2. Apply sealant to the bolt threads.

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the retainer with the 5 bolts.
      GTY628244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 12 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.

  60. INSTALL HOSE 
    GTY230616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Attach the clamp and install the hose.
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