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Home >> Toyota >> 1983 >> Land Cruiser 2D Utility >> Repair and Diagnosis >> Transmission >> Transfer Case - Land Cruiser >> Transfer Case Disassembly

Transfer Case Disassembly

  1. Remove speedometer driven gear, bolt and retainer. Remove transfer shift lever assembly. Check rear output shaft bearing preload. Preload should be 15-25 INCH lbs. (1.7-2.8 N.m) for new bearings and 6-10 INCH lbs. (.68-1.1 N.m) for used bearings. Remove detent balls and springs. Remove transmission output shaft cover and gasket.
  2. Shift transfer case into 4WD Low range. Remove transmission output shaft nut and transfer case companion flange nuts. Remove both companion flanges. Remove rear output shaft bearing retainer and gasket. Remove idler gear shaft lock plate. Remove PTO cover on models not equipped with PTO.
  3. Measure idler gear thrust clearance through PTO opening. Clearance should be .0108-.0246" (.274-.625 mm). If clearance exceeds specifications, idler gear thrust washer will need to be replaced at reassembly. Remove transfer case-to-intermediate plate attaching bolts.
  4. Separate transfer case from intermediate plate. Remove speedometer drive gear and spacer from rear output shaft. Remove rear output shaft together with range shift fork and shift shaft. Drive roll pin out of range shift fork and separate fork from shaft. See Figure.
  5. Remove idler gear and shaft along with thrust washer, needle bearings and spacer. Using a puller, remove bearing retainer from intermediate plate. Heat retainer to 175°F (80°C) and press outer race out of bearing retainer. Remove front drive clutch sleeve, shift fork and shift shaft.
  6. Drive roll pin out of front drive shift fork and separate shift shaft from fork. Remove transmission output shaft rear bearing using a puller. Remove PTO drive gear and spacer. Using a puller, remove transmission output gear. Remove intermediate plate and gasket from transmission.
  7. Remove spacer and steel ball from transmission output shaft. Using a press, remove transfer case front output shaft from intermediate plate. Measure clearance between output shaft bearings and high and low gears on rear output shaft. Clearance should be .0039-.0098" (.10-.25 mm). See Figure.
  8. Remove snap ring from front of rear output shaft. Using a press, remove low gear and bearing from rear output shaft. Press high gear and bearing off front of rear output shaft. Remove clutch sleeve from rear output shaft
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