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Transfer (4WD): Reassembly

  1. INSTALL REAR BEARING OUTER RACE 

    Using SST and a press, install the outer race.

    SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)

    Fig 1: Installing Rear Bearing Outer Race
    G02639994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT BEARING OUTER RACE 
    1. Install the washer to the transfer case.

      HINT:

      First install a washer of the same thickness as before.

    2. Using SST, bolt and nut, install outer race to the transfer case.

      SST 09950-60010 (09951-00610, 09951-00620), 09950-60020 (09951-00790, 09951-00810)

      Fig 2: Installing Front Bearing Outer Race To Transfer Case
      G02639995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL BEARING OUTER RACE LH 
    1. Install the washer to the transfer case.

      HINT:

      First install a washer of the same thickness as before.

    2. Using SST and a press, install outer race to the transfer case.

      SST 09950-60020 (09951-00710), 09950-70010 (09951-07200)

      Fig 3: Installing Bearing Outer Race LH To Transfer Case
      G02639996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL DRIVEN PINION 
    1. Using SST and a press, install the front bearing inner race to the driven pinion.

      SST 09316-60011 (09316-00041)

      Fig 4: Installing Front Bearing Inner Race To Driven Pinion
      G02639997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the driven pinion to the transfer case.
      Fig 5: Installing Driven Pinion To Transfer Case
      G02639998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the new spacer and the rear bearing inner race to the driven pinion.
      4. Fig 6: Installing Spacer And Rear Bearing Inner Race To Driven Pinion
      G02639999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat gear oil (LSD type) to the thread of a new lock nut.
    5. Using SST, install the lock nut.

      SST 09326-20011, 09556-16030

      Fig 7: Installing Lock Nut
      G02640000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      308 N.m (3,142 kgf.cm, 227 ft.lbf) for use with SST 

      349 N.m (3,560 kgf.cm, 257 ft.lbf) 

      HINT:

      • Using a torque wrench with a fulcrum length of 380 mm (15.03 in.).
      • This torque value is effective in case the SST is parallel to torque wrench.
        NOTE: Do not tighten the nut until the final adjustment of the preload, tooth contact and backlash is completed.
  5. CHECK DRIVEN PINION PRELOAD 

    Using SST and a torque wrench, measure the driven pinion preload.

    SST 09326-2001

    Fig 8: Measuring Driven Pinion Preload
    G02640001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Preload (at starting): 

    New bearing: 

    0.9 to 1.4 N.m (9 to 14 kgf.cm, 7.8 to 12.4 in.lbf) 

    Reused bearing: 

    0.8 to 1.1 N.m (8 to 11 kgf.cm, 7.0 to 9.7 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 torque wrench.
    • If the preload is not sufficient, adjust the driven pinion by tightening the lock nut by 5° to 10° and measuring the preload until the preload is within the standard value.
    • If the preload is more than 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.
  6. ASSEMBLE CENTER DIFFERENTIAL CONTROL COUPLING 
    1. Clean the contact surface of the ring gear and center differential control coupling.
    2. Heat the ring gear in water and boil for 10 minutes.
      3. Fig 9: Heating Ring Gear In Boiling Water
      G02640002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Carefully remove the ring gear from the water.
    4. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the center differential control coupling.
      5. Fig 10: Installing Ring Gear To Center Differential Control Coupling
      G02640003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 12 bolts.

      Torque: 77.5 N.m (791 kgf.cm, 57 ft.lbf) 

    6. Using SST and a press, install the center differential case tapered roller bearing inner race LH and RH.

      SST 09223-00010, 09506-35010, 09950-60010 (09951-00420)

      Fig 11: Installing Center Differential Case Tapered Roller Bearing Inner Race LH And RH
      G02640004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY 
    Fig 12: Installing Center Differential Control Coupling Assembly
    G02640005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING OUTER RACE RH 
    1. Install the washer to the bearing retainer RH.
    2. Using SST and a press, install the outer race to the bearing retainer RH.

      SST 09550-60010 (09951-00620), 09950-70010 (09951-07150)

      Fig 13: Installing Outer Race To Bearing Retainer RH
      G02640006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL BEARING RETAINER RH 
    1. Place the transfer with the installation surface for the retainer upward.
    2. Do centering of the center differential control coupling assembly and the case.
      Fig 14: Centering Center Differential Control Coupling Assembly & Case
      G02640007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Insert the SST into the retainer.

      SST 09387-00090

      Fig 15: Inserting SST Into Retainer
      G02640008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Insert the SST straight down without making its tip interfered the lip of the oil seal.
    4. Insert the retainer and the SST into the case together as a unit.
      Fig 16: Inserting Retainer And SST Into Case Together As Unit
      G02640009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not make the transfer case, bearing retainer RH and SST interfere with the center differential control coupling.
      • Do not damage the retainer O-ring only after adjusting the backlash, tooth contact and total pre-loading.

      HINT:

      When the retainer cannot be inserted in the case, give a slight blow with a plastic hammer and insert it.

    5. After inserting the retainer in the case, remove the SST.
      6. Fig 17: Removing SST
      G02640010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 7 bolts.

      Torque: 28 N.m (286 kgf.cm, 115 ft.lbf) 

  10. INSPECT BACKLASH 

    Using a dial indicator, measure the backlash of the ring gear at 3 positions at least.

    Fig 18: Measuring Backlash Of Ring Gear
    G02640011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.) 

    HINT:

    The measure values should be used as reference when selecting washer, so take a note of the values.

    If the backlash is not within the specification replace the washer on the ring gear side with one of a different thickness using the following procedure.

    Fig 19: Identifying Washer For Backlash Adjusting
    G02640012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Washer thickness: mm (in.) 

    WASHER THICKNESS SPECIFICATION CHART

    Mark Thickness Mark Thickness
    AA 2.07 (0.0815) FB 2.55 (0.1004)
    AB 2.10 (0.0827) FC 2.58 (0.1016)
    AC 2.13 (0.0839) GA 2.61 (0.1028)
    BA 2.16 (0.0850) GB 2.64 (0.1039)
    BB 2.19 (0.0862) GC 2.67 (0.1051)
    BC 2.22 (0.0874) HA 2.70 (0.1063)
    CA 2.25 (0.0886) HB 2.73 (0.1075)
    CB 2.28 (0.0898) HC 2.76 (0.1087)
    CD 2.31 (0.0909) JA 2.79 (0.1098)
    DA 2.34 (0.0921) JB 2.82 (0.1110)
    DB 2.37 (0.0933) JC 2.85 (0.1122)
    DC 2.40 (0.0945) KA 2.88 (0.1134)
    EA 2.43 (0.0957) KB 2.91 (0.1146)
    EB 2.46 (0.0969) KC 2.94 (0.1157)
    EC 2.49 (0.0980) LA 2.97 (0.1169)
    FA 2.52 (0.0992) LB 3.00 (0.1181)
  11. INSPECT TOOTH CONTACT PATTERN 
    1. Coat 3 or 4 teeth at the 4 different positions on the ring gear with red lead.
      2. Fig 20: Coating Teeth On Ring Gear With Red Lead
      G02640013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Rotate the ring gear, inspect the teeth pattern.
      Fig 21: Inspecting Teeth Pattern
      G02640014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. If the teeth are not contacting properly, select the proper washer again.
      Fig 22: Identifying Washer Tooth Contact Adjusting
      G02640015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Washer thickness: mm (in.) 

      WASHER THICKNESS SPECIFICATION CHART

      Mark Thickness Mark Thickness
      AA 1.20 (0.0472) HC 1.43 (0.0563)
      AB 1.21 (0.0476) JA 1.44 (0.0567)
      AC 1.22 (0.0480) JB 1.45 (0.0571)
      BA 1.23 (0.0484) JC 1.46 (0.0575)
      BB 1.24 (0.0488) KA 1.47 (0.0579)
      BC 1.25 (0.0492) KB 1.48 (0.0583)
      CA 1.26 (0.0496) KC 1.49 (0.0587)
      CB 1.27 (0.0500) LA 1.50 (0.0591)
      CC 1.28 (0.0504) LB 1.51 (0.0594)
      DA 1.29 (0.0508) LC 1.52 (0.0598)
      DB 1.30 (0.0512) MA 1.53 (0.0602)
      DC 1.31 (0.0516) MB 1.54 (0.0606)
      EA 1.32 (0.0520) MC 1.55 (0.0610)
      EB 1.33 (0.0524) NA 1.56 (0.0614)
      EC 1.34 (0.0528) NB 1.57 (0.0618)
      FA 1.35 (0.0531) NC 1.58 (0.0622)
      FB 1.36 (0.0535) PA 1.59 (0.0626)
      FC 1.37 (0.0539) PB 1.60 (0.0630)
      GA 1.38 (0.0543) PC 1.61 (0.0634)
      GB 1.39 (0.0547) QA 1.62 (0.0638)
      GC 1.40 (0.0551) QB 1.63 (0.0642)
      HA 1.41 (0.0555) QC 1.64 (0.0646)
      HB 1.42 (0.0559) RA 1.65 (0.0650)
  12. ADJUST TOTAL PRELOAD 

    Using SST and a torque wrench, measure the total preload.

    SST 09326-20011

    Fig 23: Measuring Preload
    G02640016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Total preload: 

    New bearing: 

    Driven pinion preload + 0.2 to 0.4 N.m (2 to 4 kgf.cm, 1.8 to 3.5 in.lbf) 

    Reused bearing: 

    Driven pinion preload + 0.1 to 0.3 N.m (1 to 3 kgf.cm, 0.9 to 2.6 in.lbf) 

    HINT:

    Using a torque wrench with a fulcrum length of 160 mm (6.3 in.).

    HINT:

    Turn the driven pinion counterclockwise and clockwise several times.

    If the preload is not as specified, select a proper washer again.

    Fig 24: Identifying Washer Preload Adjusting
    G02640017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Washer thickness: mm (in.) 

    WASHER THICKNESS SPECIFICATION CHART

    Mark Thickness Mark Thickness
    AA 1.47 (0.0579) GB 2.04 (0.0803)
    AB 1.50 (0.0591) GC 2.07 (0.0815)
    AC 1.53 (0.0602) HA 2.10 (0.0827)
    BA 1.56 (0.0614) HB 2.13 (0.0839)
    BB 1.59 (0.0626) HC 2.16 (0.0850)
    BC 1.62 (0.0638) JA 2.19 (0.0862)
    CA 1.65 (0.0650) JB 2.22 (0.0874)
    CB 1.68 (0.0661) JC 2.25 (0.0886)
    CC 1.71 (0.0673) KA 2.28 (0.0898)
    DA 1.74 (0.0685) KB 2.31 (0.0909)
    DB 1.77 (0.0697) KC 2.34 (0.0921)
    DC 1.80 (0.0709) LA 2.37 (0.0933)
    EA 1.83 (0.0720) LB 2.40 (0.0945)
    EB 1.86 (0.0734) LC 2.43 (0.0957)
    EC 1.89 (0.0744) MA 2.46 (0.0969)
    FA 1.92 (0.0756) MB 2.49 (0.0980)
    FB 1.95 (0.0768) MC 2.52 (0.0992)
    FC 1.98 (0.0780) NA 2.55 (0.1004)
    GA 2.01 (0.0791) NB 2.58 (0.1016)
  13. REMOVE BEARING RETAINER RH 
    1. Remove the 7 bolts.
      Fig 25: Removing Bolts Of Bearing Retainer RH
      G02640018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver and a hammer, make clearance by hitting between the bearing retainer RH and the transfer case.
      Fig 26: Using Screwdriver And Hammer To Make Clearance By Hitting Between Bearing Retainer RH And Transfer Case
      G02640019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the bearing retainer RH from the transfer case.

      SST 09520-10021

      Fig 27: Removing Bearing Retainer RH From Transfer Case
      G02640020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, remove the outer race and washer from the bearing retainer RH.

      SST 09308-00010

      Fig 28: Removing Outer Race And Washer From Bearing Retainer RH
      G02640021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. ASSEMBLE BEARING RETAINER RH 
    1. Install the side gear shaft holder bearing to the bearing retainer RH.
    2. Using snap ring pliers, install the snap ring.
      3. Fig 29: Installing Snap Ring
      G02640022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the oil seal lip with MP grease.
    4. Using SST and a press, install the oil seal to the bearing retainer RH.

      SST 09950-60010 (09951-00370, 09951-00540, 09952-06010), 09950-70010 (09951-07150)

      5. Fig 30: Installing Oil Seal To Bearing Retainer RH
      G02640023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the washer.
    6. Using SST and a press, install the outer race to the bearing retainer RH

      SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)

      Fig 31: Installing Outer Race To Bearing Retainer RH
      G02640024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Coat new 2 O-rings with gear oil, and install them to the bearing retainer RH.
      Fig 32: Installing O-Rings To Bearing Retainer RH
      G02640025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL BEARING RETAINER RH 
    1. Place the transfer with the installation surface for the retainer upward.
      2. Fig 33: Placing Transfer With Installation Surface For Retainer Upward
      G02640026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Do centering of the center differential control coupling assembly and the case.
    3. Insert the SST into the retainer.

      SST 09387-00090

      Fig 34: Inserting SST Into Retainer
      G02640027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Insert the SST straight down without making its tip interfered the lip of the oil seal.
    4. Insert the retainer and the SST into the case together as a unit.
      Fig 35: Inserting Retainer & SST Into Case As Unit
      G02640028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not strongly make the case and retainer interfered. Neither the SST or the center differential control coupling.
      • Pay attention to the scratches and the curving up of the retainer O-ring only after adjusting the backlash, tooth contact and total pre-loading.
      Fig 36: Identifying Oil Seal & O-Ring
      G02640029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      When the retainer cannot be inserted in the case, give a slight blow with a plastic hammer and insert it.

    5. After inserting the retainer in the case, remove the SST.
    6. Install the 7 bolts.

      Torque: 28 N.m (286 kgf.cm, 115 ft.lbf) 

      NOTICE: 

  16. RECHECK TOTAL PRELOAD (See step   12 ) 
  17. INSTALL OIL SEAL 
    1. Coat the oil seal lip with MP grease.
    2. Using SST, install the oil seal to the bearing retainer RH.

      SST 09223-46011

      Fig 37: Installing Oil Seal To Bearing Retainer RH
      G02640030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the oil seal lip with MP grease.
    4. Using SST, install the oil seal to the transfer case.

      SST 09387-00010, 09950-70010 (09951-07150)

      Fig 38: Installing Oil Seal To Transfer Case
      G02640031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL CENTER DIFFERENTIAL LOCK SLEEVE 
    1. Coat new O-ring with gear oil, install it to the center differential lock sleeve.
      Fig 39: Installing O-Ring To Center Differential Lock Sleeve
      G02640032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the center differential lock sleeve to the transfer case.

      SST 09950-60010 (09951-00600), 09950-70010 (09951-07150)

      Fig 40: Installing Center Differential Lock Sleeve To Transfer Case
      G02640033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using snap ring pliers, install the snap ring.
      Fig 41: Installing Snap Ring
      G02640034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. STAKE LOCK NUT 

    Using a chisel and a hammer, stake the lock nut.

    Fig 42: Using Chisel And Hammer To Stake Lock Nut
    G02640035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL EXTENSION HOUSING 
    1. Coat the oil seal lip with MP grease.
    2. Using SST, install the oil seal to the extension housing.

      SST 09950-60010 (09951-00380, 09951-00590, 09952-06010) 09950-70010 (09951-07150)

      Fig 43: Installing Oil Seal To Extension Housing
      G02640036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, install the dust deflector to the extension housing.

      SST 09950-60010 (09951-00640), 09950-70010 (09951-07150)

      Fig 44: Installing Dust Deflector To Extension Housing
      G02640037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the extension housing and the transfer case.
    5. Apply FIPG to the extension housing.

      FIPG: 

      Part No.08826-00100, THREE BOND 1281 or equivalent 

      Fig 45: Identifying Seal Bend Width
      G02640038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the extension housing with 4 bolts.

      Torque: 25.5 N.m (260 kgf.cm, 19 ft.lbf) 

      Fig 46: Installing Bolts & Extension Housing
      G02640039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL STUD BOLT 

    Install the 4 new stud bolts to the transfer case.

    Fig 47: Installing Stud Bolts To Transfer Case
    G02640040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf) 

    HINT:

    • From the bottom side of the stud bolt shown in Fig 47 it should be installed to the case.
    • Install the stud bolt to the transfer case which has sealer applied on it.
  22. INSTALL PIN 

    Using a plastic hammer, install the 4 pins.

    23. Fig 48: Installing Pins
    G02640041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE TRANSFER FROM OVERHAUL ATTACHMENT 
  24. INSTALL CASE COVER 
    1. Install the oil deflector with a bolt to the case cover.
      Fig 49: Installing Bolt & Oil Deflector
      G02640042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.5 N.m (66 kgf.cm, 58 in.lbf) 

      NOTE: Pay due attention to the direction of deflector bending.
    2. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the case cover and the transfer case.
    3. Apply FIPG to the case cover.

      FIPG: 

      Part No.08826-00100, THREE BOND 1281 or equivalent 

      Fig 50: Identifying Seal Bend Width
      G02640043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the No. 1 case cover with 2 new seal bolts and 6 bolts.
      Fig 51: Installing No. 1 Case Cover With Seal Bolts & Bolts
      G02640044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 19.6 N.m (200 kgf.cm, 14 ft.lbf) 

  25. INSTALL INTERMEDIATE SHAFT 
  26. INSTALL GASKET 

    Coat new gasket with ATF, install it to the transfer case.

    Fig 52: Installing Gasket To Transfer Case
    G02640045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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