Transfer Assembly: Disassembly

WARNING: This page is about a different car, the 2002 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

Remove breather hose .
Remove vehicle speed sensor driven gear .
1. Remove the bolt and driven gear.
Remove motor actuator .
1. Remove the 4 bolts and motor actuator.
Fig 1: Locating Bolts For Removal Of Motor Actuator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove output gear from front case .

Fig 2: Removing Output Gear From Front Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove screw plug, spring and ball .
1. Using a torx socket wrench (T40), remove the screw plug.
2. Using a magnetic finger, remove the spring and ball.
Remove transfer indicator switch .
1. Remove the 3 transfer indicator switches and 3 gaskets.
Remove front extension housing .
1. Remove the 6 bolts and front extension housing.
  
  Fig 4: Locating Front Extension Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If necessary, tap the front extension housing lightly with a plastic hammer.
Remove clutch sleeve with shift fork No. 2 shaft and shift fork No. 2 .

Fig 5: Removing Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Separate shift fork No. 2 shaft and shift fork No. 2 .
1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the shift fork No. 2 shaft.
  
  Fig 6: Removing Snap Rings From Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Separate the shift fork No. 2 shaft and shift fork No. 2.
Remove rear extension housing .
1. Remove the 9 bolts and rear extension housing.
  
  Fig 7: Locating Rear Extension Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If necessary, tap the rear extension housing lightly with a plastic hammer.
Remove adjusting shims .
Remove oil strainer from rear case .
1. Remove the 2 bolts and oil strainer.
Fig 8: Locating Oil Strainer Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove case cover .
1. Remove the 5 bolts.
  
  Fig 9: Locating Case Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap the case cover and remove it.
  
  Fig 10: Using Brass Bar & Hammer To Remove Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Separate front case and rear case .
1. Using a snap ring expander, remove the snap ring from the rear case.
  
  Fig 11: Removing Snap Ring From Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 8 bolts.
  
  Fig 12: Locating Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and hammer, tap the rear case and separate it.
Remove 2 bearing races from rear case .

Fig 13: Removing Bearing Races From Rear Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove input shaft assembly .
1. Using a plastic hammer, remove the input shaft assembly from the front case.
  
  Fig 14: Removing Input Shaft Assembly From Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove idler gear assembly with center differential assembly, shift fork No. 1 and shift fork No. 1 shaft from front case .

Fig 15: Removing Idler Gear Assembly With Center Differential Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Separate shift fork No. 1 and shift fork No. 1 shaft .
1. Using a pin punch and hammer, drive out the slotted spring pin.
  
  Fig 16: Driving Out Slotted Spring Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Separate the shift fork No. 1 and shift fork No. 1 shaft.
Remove shift outer lever and inner lever .
1. Remove the nut and washer from the shift outer lever.
2. Using a brass bar, hammer and socket wrench, tap out the lever lock pin.
  
  Fig 17: Tapping Out Lever Lock Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the shift outer lever, washer and inner lever from the front case.
If necessary, replace inner shift lever oil seal .
1. Using a screwdriver, pry out the oil seal from the front case.
  
  Fig 18: Prying Out Oil Seal From Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply MP grease to the lip of a new oil seal.
3. Using SST and a hammer, drive in a new oil seal.
  
  Fig 19: Driving In New Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)
If necessary, replace input shaft oil seal .
1. Using SST and a hammer, drive out the oil seal.
  
  Fig 20: Driving Out Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09316-60011 (09316-00011)
2. Apply MP grease to the lip of a new oil seal.
3. Using SST and a hammer, drive in a new oil seal.
  SST 09316-60011 (09316-00011, 09316-00031)
Remove oil receiver from front case .
1. Remove the bolt and oil receiver.
  
  Fig 21: Removing Bolt & Oil Receiver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove 2 bearing races from front case .
1. Using SST, remove the bearing race (for the idler gear).
  
  Fig 22: Removing Bearing Race (For The Idler Gear)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955- 04061, 09957-04010), 09950-60010 (09951-00320)
2. Using a brass bar and hammer, remove the bearing race (for the output shaft).
  
  Fig 23: Removing Bearing Race (For The Output Shaft)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002