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Transfer Case Reassembly

  1. Using appropriate bearing driver, install rear bearing outer race.
  2. Install front bearing outer race. Install original washer in transfer case. Using appropriate race installer, install outer race to transfer case. See Fig 1.
  3. Install bearing outer race LH. Install original washer in transfer case. Using appropriate adapter and a press, install outer race to the transfer case.
  4. Install driven pinion. Using appropriate adapter and press, install the front bearing inner race to the driven pinion. Install the driven pinion in the transfer case.
    5. NOTE: Do not stake lock nut until the final adjustment of the preload, tooth contact and backlash is completed.
  5. Install a new spacer and rear bearing inner race to the driven pinion. See Figure. Using driven pinion holding adapter, install the lock nut. See Figure. Tighten lock nut to 227-257 ft. lbs. (308-349 N.m).
  6. Check driven pinion preload. Using INCH lb. torque wrench, measure the driven pinion preload (at starting). See Figure. Starting preload should be 7.8-12.4 INCH lbs. (.9-1.4 N.m) for new bearing or 7.1-9.7 INCH lbs. (.8-1.1 N.m) for used bearing.
    • If the preload is not sufficient, adjust the driven pinion by tightening the lock nut by 5-10 degrees and measuring the preload until the preload is within the standard value. If the preload is more then the standard value, replace the spacer with a new one.
    • If the tightening torque for a driven pinion nut is more than the standard value, and the preload is not sufficient, loosen the lock nut, apply gear oil on the thread and bearing surface and adjust it as described above. When the tightening torque is less than the standard value, replace the spacer with a new one.
  7. Assemble center differential control coupling. Clean the contact surface of the ring gear and center differential control coupling. Heat the ring gear in water and boil for 10 minutes. Carefully remove the ring gear from the water.
  8. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the center differential control coupling. Install the 12 bolts. Tighten bolts to specification in crisscross pattern. See TORQUE SPECIFICATIONS .
  9. Using appropriate adapter and a press, install the center differential case tapered roller bearing inner race LH and RH.
  10. Install center differential control coupling.
  11. Install center differential case tapered roller bearing outer race RH. Install original washer to the bearing retainer RH. Using appropriate bearing race installer and a press, install the outer race to the bearing retainer RH.
  12. Install Bearing Retainer RH. Put the installation surface for the bearing retainer RH of the transfer case upward. Install the center differential control coupling onto the transfer case and make the center meet each other. See Fig 2.
    13. NOTE: Do not make the transfer case, bearing retainer RH and centering tool interfere forcibly with the center differential control coupling. Pay attention for the damage and peeling off of the "O" ring in the retainer.
  13. Insert Centering tool (09387-00090) to the bearing retainer RH. See Fig 3. Install the bearing retainer RH with the centering tool to the transfer center differential control coupling. See Fig 4.
  14. When the bearing retainer cannot be inserted, hit it soft with the plastic hammer and insert it.
  15. After having inserted the bearing retainer to the transfer case, remove centering tool. Install 7 bolts and tighten to specification. See TORQUE SPECIFICATIONS .
  16. Inspect backlash. Using dial indicator, measure and record the ring gear backlash at 3 positions. See Figure. Backlash should be.004-.006" (.10-.15 mm).
  17. If the backlash is not within the specification replace the washer on the ring gear side with one of a different thickness. See Fig 5. Washers available range in thickness of.082-.118" (2.07-3.00 mm) in increments of.0012" (.030 mm).
  18. Inspect gear tooth contact pattern. Coat 3 or 4 teeth at four different positions on ring gear using Prussian Blue. Rotate the ring gear, inspect the contact pattern on teeth. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION.
  19. If the teeth are not contacting properly, select and install the proper washer. See Fig 6. Washers available range in thickness of.047-.065" (1.20-1.65 mm) in increments of.0004" (.01 mm).
  20. Check and adjust total preload. Using INCH lb. torque wrench, measure the total preload. See Figure. Total preload should be 9.7-15.9 INCH lbs. (1.1-1.8 N.m) for new bearing or 8.0-12.4 INCH lbs. (.9-1.4 N.m) for used bearing.
  21. If total preload is not within standard, select and install the proper washer. See Fig 7. Washers available range in thickness of.058-.102" (1.47-2.58 mm) in increments of.0012" (.03 mm).
  22. Remove bearing retainer RH. Remove 7 retaining bolts.
  23. Using a screwdriver and hammer, make clearance by hitting gap between the bearing retainer RH and transfer case.
  24. Using appropriate puller and slide hammer, remove the bearing retainer RH from the transfer case.
  25. Using appropriate puller and slide hammer, remove the outer race and washer.
  26. Assemble bearing retainer RH. Install the side gear shaft holder bearing to the bearing retainer RH. Using snap ring pliers, install the snap ring. See Figure. Coat new oil seal lip with multi-purpose grease.
  27. Using appropriate bearing race driver and press, install the oil seal to the bearing retainer RH. Install the washer.
  28. Using appropriate bearing race driver and press, install the bearing race into the bearing retainer RH.
  29. Coat 2 new "O" rings with gear oil, then install them on the bearing retainer RH.
  30. Install bearing retainer RH. Put the installation surface for the bearing retainer RH of the transfer case upward. Install the center differential control coupling onto the transfer case and make the center meet each other. See Fig 2.
    31. NOTE: Do not make the transfer case, bearing retainer RH and centering tool interfere forcibly with the center differential control coupling. Pay attention for the damage and peeling off of the "O" ring on the retainer.
  31. Insert Centering tool (09387-00090) to the bearing retainer RH. See Fig 3. Install the bearing retainer RH with the centering tool to the transfer center differential control coupling. See Fig 4.
  32. Install 7 bolts and tighten to specification. See TORQUE SPECIFICATIONS . Check total preload. Go to step  20.
  33. Install oil seal. Coat a new oil seal lip with multi-purpose grease. Using appropriate driver, install oil seal to the bearing retainer RH.
  34. Coat new oil seal lip with multi-purpose grease. Using appropriate driver, install oil seal to the transfer case.
  35. Install center differential lock sleeve. Coat a new "O" ring with multi-purpose grease and install it to the center differential lock sleeve.
  36. Using appropriate driver, install the center differential lock sleeve to the transfer case. Using snap ring pliers, install the snap ring.
  37. Using a chisel and a hammer, stake the lock nut.
  38. Install extension housing. Coat oil seal lip with multi-purpose grease. Using appropriate seal driver, install the oil seal to the extension housing. Using appropriate adapter and a press, install the dust deflector to the extension housing.
  39. Ensure contacting surface of extension housing and transfer case are clean. Apply appropriate gasket sealant to extension housing. Install the extension housing with 4 bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
    40. NOTE: The shorter threaded portion of stud bolt should be installed in transfer case.
  40. Install 4 stud bolts to the transfer case.
  41. Using a plastic hammer, install 4 pins. Remove transfer case from holding fixture.
    42. NOTE: Ensure angle bend of deflector faces inward.
  42. Install No. 1 case cover. Install the oil deflector with the bolt to the No. 1 case cover. Tighten bolt to 58 INCH lbs. (6.5 N.m).
  43. Ensure contacting surface of case cover and transfer case are clean. Apply appropriate gasket sealant to case cover. Install the case cover with 2 new bolts at 2 and 3 o'clock positions. Install remaining 6 bolts. Tighten bolts to specification.
  44. Install No. 2 intermediate side gear. Install gasket. Coat new gasket with A/T fluid and install it to the transfer case.
Fig 1: Installing Transfer Case Outer Bearing Race
G00079163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Installing Bearing Retainer RH
G00079164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Identifying Centering Tool Installation
G00079165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 4: Installing Bearing Retainer RH With Centering Tool
G00079166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 5: Identifying Backlash Adjustment Washer Location
G00079167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 6: Identifying Gear Tooth Contact Pattern Adjustment Washer Location
G00079168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 7: Identifying Total Preload Adjustment Washer Location
G00079169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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