Transfer Assembly: Reassembly

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.

Inspect shift fork No. 2 and clutch sleeve clearance .
1. Using a feeler gauge, measure the clearance between the shift fork No. 2 and clutch sleeve.
  
  Fig 1: Measuring Clearance Between Shift Fork No. 2 & Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Standard clearance :
  1. 0.10 - 0.40 mm (0.0039 - 0.0157 in.)
3. Maximum clearance :
  1. 0.40 mm (0.0157 in.)
Install the bearing race (for the output shaft) .
1. Using SST and a press, install the bearing race.
  
  Fig 2: Installing Bearing Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09316-60011 (09316-00011, 09316-00031), 09950-60020 (09951-00890)
Install the bearing race (for the idler gear) .
1. Using SST and a press, install the bearing race.
  
  Fig 3: Installing Bearing Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09316-60011 (09316-00011, 09316-00031), 09950-60020 (09951-00790)
Install oil receiver to front case .
1. Install the oil receiver and bolt.
  
  Fig 4: Installing Oil Receiver & Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)
Install shift outer lever and inner lever .
1. Install the shift inner lever, washer and outer lever to the front case.
2. Using a pin punch, hammer and socket wrench, tap in the lever lock pin.
  
  Fig 5: Tapping In Lever Lock Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the washer and nut to the shift outer lever.
  Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)
Assemble shift fork No. 1 and shift fork No. 1 shaft .
1. Assemble the shift fork No. 1 and shift fork No. 1 shaft.
2. Using a pin punch and hammer, drive in the slotted spring pin.
  
  Fig 6: Driving In Slotted Spring Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install idler gear assembly with center differential assembly, shift fork No. 1 and shift fork No. 1 shaft to front case

Fig 7: Installing Idler Gear Assembly With Center Differential Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Set the shift inner lever into the fork head part of the shift fork No. 1 securely.
Install input shaft assembly .
Install 2 bearing races to rear case .
Assembly front case and rear case .
1. Apply FIPG to the front case.
  
  Fig 8: Applying FIPG To Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  FIPG :
  1. Part No. 08826-00090, THREE BOND 1281 or equivalent
2. Assemble the front case and rear case.
3. Apply liquid sealer to the "A" bolt threads.
  
  Fig 9: Applying Liquid Sealer To "A" Bolt Threads
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Sealant :
  1. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
4. Install the 8 bolts.
  Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
Assemble front case and rear case .
1. Using a snap ring expander, install the snap ring to the rear case.
  
  Fig 10: Installing Snap Ring To Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install case cover .
1. Apply FIPG to the rear case.
  
  Fig 11: Applying FIPG To The Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  FIPG :
  1. Part No. 08826-00090, THREE BOND 1281 or equivalent
2. Install the case cover.
3. Apply liquid sealer to the bolt threads.
  Sealant :
  1. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
4. Install the 5 bolts.
  
  Fig 12: Locating Bolts For Installation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
Install oil strainer to rear case .
1. Install the oil strainer and 2 bolts.
  
  Fig 13: Installing Oil Strainer & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf)
Select adjusting shim for idler gear rear taper roller bearing .
1. Using vernier calipers, measure dimension "A".
  
  Fig 14: Measuring Dimension "A" Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
3. Using a steel straight edge and feeler gauge, measure the clearance of dimension "B".
  
  Fig 15: Measuring Clearance Of Dimension "B"
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Calculate the required thickness of the adjusting shim.
  Thickness: Dimension "A" + Dimension "B" + [0.022 0.049 mm, (0.0009 - 0.0019 in.)]
5. From the table in Fig 16, select a shim so that its thickness is within the range of the calculation.
  
  Fig 16: Identifying Shim Thickness Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Select adjusting shim for output shaft taper roller bearing .
1. Using a steel straight edge and feeler gauge, measure the clearance of dimension "C".
  
  Fig 17: Measuring Clearance Of Dimension "C"
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
3. Using a steel straight edge and vernier calipers with depth gauge, measure dimension "D".
  
  Fig 18: Measuring Dimension "D"
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Dimension "D" is the straight edge thickness (Dimension "F") subtracted from dimension "E" in Fig 18.
  Dimension "D": Dimension "E" - Dimension "F"
5. Using a steel straight edge and vernier calipers with depth gauge, measure dimension "G".
  
  Fig 19: Measuring Dimension "G"
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Dimension "G" is the straight edge thickness (Dimension "F") subtracted from Dimension "H".
  Dimension "G": Dimension "H" - Dimension "F"
7. Calculate the required thickness of the adjusting shim.
  Thickness: Dimension "G" - (Dimension "D" - Dimension "C") + [0.014 ~ 0.039 mm, (0.0006 ~ 0.0015 in.)]
8. From the table in Fig 20, select a shim so that its thickness is within the range of the calculation.
  
  Fig 20: Identifying Shim Thickness Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install rear extension housing .
1. Apply FIPG to the rear extension housing.
  
  Fig 21: Applying FIPG To Rear Extension Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  FIPG :
  1. Part No. 08826-00090, THREE BOND 1281 or equivalent
2. Install the rear extension housing and 9 bolts.
  
  Fig 22: Locating Bolts For Installation Of Rear Extension Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
Assemble shift fork No. 2 shaft and shift fork No. 2 .
1. Install the shift fork No. 2 to the shift fork No. 2 shaft.
2. Install the 3 snap rings to the shift fork No. 2 shaft.
Install clutch sleeve with shift fork No. 2 shaft and shift fork No. 2 .
NOTE: Make sure to install the clutch sleeve in the correct direction.

Fig 23: Installing Shift Fork No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install front extension housing .
1. Apply FIPG to the front extension housing.
  
  Fig 24: Applying FIPG To Front Extension Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  FIPG :
  1. Part No. 08826-00090, THREE BOND 1281 or equivalent
2. Install the front extension housing and 6 bolts.
  
  Fig 25: Locating Bolts For Installation Of Front Extension Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
  
  NOTE: Set the clutch sleeve in differential lock condition.
Install transfer indicator switch .
1. Install the 3 transfer indicator switches with 3 new gaskets.
  Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
Install ball, spring and screw .
1. Install the ball and spring.
  
  Fig 26: Installing Ball & Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply liquid sealer to the screw plug threads.
  Sealant :
  1. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
3. Using a torx socket wrench (T40), install the screw plug.
  Torque: 19 N.m (190 kgf.cm, 14 ft.lbf)
Install output gear to front case .

Fig 27: Installing Output Gear To Front Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- Apply gear oil to the output gear.
- Do not turn the output gear.
Install motor actuator .
1. Apply FIPG to the motor actuator.
  
  Fig 28: Applying FIPG To Motor Actuator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  FIPG :
  1. Part No. 08826-00090, THREE BOND 1281 or equivalent
  NOTE: Set the motor actuator in differential lock condition.
  
  Fig 29: Setting Motor Actuator In Differential Lock Condition
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the motor actuator and 4 bolts.
  
  Fig 30: Locating Bolts For Installation Of Motor Actuator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
Install speed sensor drive gear .
1. Install the driven gear and bolt.
  Torque: 11 N.m (115 kgf.cm, 8 ft.lbf)
Install breather hose .