Transfer Case Reassembly
- Install range shift clutch sleeve onto rear output shaft. Coat rear output shaft with grease and install high and low speed gears. Press rear output shaft bearing inner races onto shaft. Install front drive clutch hub onto front of rear output shaft and secure with a selective thickness snap ring.
- Snap ring should be selected to keep axial play between .0012" (.003 mm) and .0118" (.299 mm). Apply gear oil to all moving parts on rear output shaft. Press front output shaft into intermediate plate. Install steel ball onto transmission output shaft and then slide collar over shaft and ball.
- Coat transmission output shaft seal with grease. Install intermediate plate to transmission using sealer on all attaching bolts. Press transmission output gear onto shaft. Install spacer and PTO drive gear onto transmission output shaft. Press transmission output shaft rear bearing onto shaft and secure with a washer and lock nut. Install lock nut finger tight only.
- Install front drive shift shaft into shift fork and secure with a roll pin. Place front drive shift sleeve into fork and install assembly into intermediate plate. Press rear output shaft front bearing outer race into bearing retainer. Tap bearing retainer into intermediate plate.
- Install range shift fork onto shift shaft and secure with roll pin. Place range shift fork onto shift sleeve. Install rear output shaft and shift fork assembly into intermediate plate. Coat the idler gear thrust washer with grease and stick to intermediate plate, making sure that tab on thrust washer engages slot on plate.
- Install front "O" ring onto idler gear shaft. Place idler gear on intermediate plate and install idler gear shaft so that 2" (50 mm) of shaft extends beyond gear. Install spacer and speedometer drive gear onto rear output shaft.
- If idler gear thrust clearance was not to specifications at disassembly, select a thrust washer that will correct clearance. Clearance should be .0108-.0246" (.275-.625 mm). Coat idler gear thrust washer with grease and place on transfer case, making sure that tab on thrust washer engages slot in case.
- Install transfer case onto intermediate plate, taking care to engage range selector lever tip with groove in range shift shaft. Install transfer case attaching bolts using liquid sealer.
- Rotate idler gear shaft so that locking groove aligns with bolt hole. Install idler shaft rear "O" ring and tap shaft into place. Secure shaft with locking plate and bolt. Check operation of range shift lever to ensure smooth operation and proper engagement.
- Recheck idler gear thrust clearance. Install rear bearing retainer, making sure that rib on case and retainer line up. Shift transfer case to 4WD Low range. Install front and rear companion flanges and secure with washers and lock nuts. Hold output shaft stationary and tighten companion flange nuts and transmission output shaft nut.
- Disengage front drive and check rear output shaft bearing preload. Rotating torque should be 13-24 INCH lbs. (1.47-2.71 N.m) for new bearings and 6-10 INCH lbs. (.678-1.13 N.m) for used bearings.
- If preload is not within specifications, preload shims must be changed. The preload shims are located between the rear bearing retainer and the rear output shaft bearing outer race.
- Install PTO cover (if applicable) and transmission output shaft cover using liquid sealer on all bolts. Install shifter assembly and check for smooth operation and proper engagement of all gear ranges.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002