Transfer (4WD): Disassembly

1. Remove the 8 bolts.
   Fig 3: Removing Bolts Of No. 1 Case Cover

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2. Using a brass bar and hammer, remove the No. 1 case cover.
   NOTE: Be careful not to damage the transfer case and case cover No. 1.
   Fig 4: Removing No. 1 Case Cover

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3. Remove the bolt and breather oil deflector from the case cover No. 1.
Fig 5: Removing Bolt & Breather Oil Deflector From Case Cover No. 1
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1. Using a plastic hammer, remove the dust deflector from the extension housing.
   Fig 6: Removing Dust Deflector From Extension Housing

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2. Using SST, remove the oil seal from the extension housing.

   SST 09308-00010

   Fig 7: Removing Oil Seal From Extension Housing

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   NOTE: Be careful not to damage the extension housing.
3. Remove the 4 bolts.
   Fig 8: Removing Bolts

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4. Using a plastic hammer, remove the extension housing.
   Fig 9: Removing Extension Housing

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1. Using SST and a torque wrench, measure the driven pinion preload of the backlash between the driven pinion and ring gear.

   SST 09326-20011

   Fig 10: Measuring Driven Pinion Preload Of Backlash Between Driven Pinion And Ring Gear

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   Preload (at starting): 

   0.9 to 1.3 N.m (9 to 13 kgf.cm, 7.8 to 12 in.lbf) 

   HINT:

   • Using a torque wrench with a fulcrum length of 160 mm (6.3 in.).
   • This torque value is effective in case that SST is parallel to a torque wrench.
2. Using SST and the torque wrench, measure the total preload.

   SST 09326-20011

   Total preload (at starting): 

   1.0 to 1.6 N.m (10 to 16 kgf.cm, 8.9 to 14 in.lbf) 

   HINT:

   • Using a torque wrench with a fulcrum length of 160 mm (6.3 in.).
   • This torque value is effective in case that SST is parallel to a torque wrench.

Using a dial indicator, measure the ring gear backlash.

Fig 11: Measuring Ring Gear Backlash

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Backlash: 0.10 to 0.15 mm 

(See  REASSEMBLY  ) 

1. Using a snap ring pliers, remove the shaft snap ring.
   Fig 12: Removing Shaft Snap Ring

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2. Using SST, remove the center differential lock sleeve.

   SST 09308-00010

   Fig 13: Removing Center Differential Lock Sleeve

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   NOTE: Be careful not to damage the center differential lock sleeve.
3. Using a screwdriver, remove the O-ring from the center differential lock sleeve.
   Fig 14: Removing O-Ring From Center Differential Lock Sleeve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the center differential lock sleeve.

Using SST, remove the oil seal from the transfer case.

SST 09308-00010

Fig 15: Removing Oil Seal From Transfer Case

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1. Using SST, remove the oil seal from the bearing retainer RH.

   SST 09308-00010

   Fig 16: Removing Oil Seal From Bearing Retainer RH

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   NOTE: Be careful not to damage the bearing retainer.
2. Remove the 7 bolts.
   Fig 17: Removing Bolts

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3. Using a screwdriver and a hammer, make clearance by hitting between the bearing retainer RH and the transfer case.
   Fig 18: Using Screwdriver And Hammer To Make Clearance By Hitting Between Bearing Retainer RH And Transfer Case

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4. Using SST, remove the bearing retainer RH from the transfer case.

   SST 09520-10021

   Fig 19: Removing Bearing Retainer RH From Transfer Case

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5. Using a screwdriver, remove 2 O-rings from the bearing retainer RH.
   Fig 20: Removing O-Rings From Bearing Retainer RH

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   NOTE: Be careful not to damage the bearing retainer RH.
6. Using soft jaws, hold the bearing retainer RH in a vise.
7. Using SST, remove the outer race, washer and oil seal from the bearing retainer RH.

   SST 09308-00010

   Fig 21: Removing Outer Race, Washer & Oil Seal From Bearing Retainer RH

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   NOTE: Be careful not to damage the bearing retainer RH.
8. Using snap ring pliers, remove the snap ring.
Fig 22: Removing Snap Ring
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9. Remove the side gear shaft holder bearing from the bearing retainer RH.

Using SST, remove the tapered roller bearing inner race LH and RH.

SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)

Fig 24: Removing Tapered Roller Bearing Inner Race LH And RH

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Using a dial indicator, check the ring gear runout.

Maximum runout: 0.1 mm (0.004 in.) 

Fig 25: Checking Ring Gear Runout

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1. Place matchmarks on both the ring gear and the center differential control coupling.
Fig 26: Placing Matchmarks On Both Ring Gear And Center Differential Control Coupling
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2. Remove the 12 bolts.
3. Using a plastic hammer, remove the ring gear.
   Fig 27: Removing Ring Gear

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Using a dial indicator, check the center differential control coupling runout.

Maximum runout: 0.07 mm (0.0028 in.) 

Fig 28: Checking Center Differential Control Coupling Runout

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1. Using SST and a hammer, unstake the lock nut.

   SST 09930-00010 (09931-00010, 09931-00020)

   Fig 29: Using SST And Hammer To Unstake Lock Nut

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2. Using SST, remove the lock nut.

   SST 09326-20011, 09556-16030

   Fig 30: Removing Lock Nut

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3. Using a press, remove the driven pinion, the rear bearing inner race and the spacer.
   Fig 31: Removing Driven Pinion, Rear Bearing Inner Race & Spacer

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   NOTE:

   • Place a waste cloth inside the case to prevent the driven pinion from dropping.
   • Keep the case level using a wood plate.
4. Using SST and a press, remove the front bearing inner race from the driven pinion.

   SST 09950-00020

   Fig 32: Removing Front Bearing Inner Race From Driven Pinion

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Using a brass bar and a hammer, remove the outer race and the washer.

Fig 33: Removing Bearing Outer Race LH And Washer

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Using a brass bar and a hammer, remove outer race and washer.

Fig 34: Removing Front Bearing Outer Race And Washer

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Using a brass bar and a hammer, remove outer race.

Fig 35: Removing Rear Bearing Outer Race

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