Transfer Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

REMOVE VEHICLE SPEED SENSOR ASSEMBLY
1. Remove the bolt and vehicle speed sensor assembly.
2. Using a small screwdriver, remove the clip and vehicle speed sensor driven gear.
3. Using a small screwdriver, remove the O-ring.
NOTE: Tape the small screwdriver tip before use.
REMOVE L4 POSITION SWITCH, NEUTRAL POSITION SWITCH AND STRAIGHT SCREW PLUG WITH 3 GASKETS
REMOVE FRONT BEARING RETAINER
Remove the 5 bolts and front bearing retainer.

NOTE: If necessary, tap the front bearing retainer with a plastic hammer to remove it.
REMOVE TRANSFER UPPER COVER
Remove the 4 bolts, transfer upper cover and oil deflector.

Fig 1: Removing Front Bearing Retainer Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT COMPANION FLANGE
1. Using a chisel and hammer, loosen the staked part of the front companion flange lock nut.
2. Using SST to hold the front companion flange, remove the front companion flange lock nut.
  1. SST 09330-00021
  Fig 2: Removing Flange Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a SST, remove the front companion flange.
  1. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
REMOVE REAR COMPANION FLANGE
Remove the rear companion flange in the same way as the front companion flange.

Fig 3: Removing Rear Companion Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXTENSION HOUSING
Remove the 5 bolts and extension housing.

NOTE: If necessary, tap the front extension housing with a plastic hammer to remove it.
REMOVE VEHICLE SPEED SENSOR DRIVE GEAR AND OUTPUT SHAFT WASHER
1. Remove the vehicle speed sensor drive gear and 2 output shaft washers.
2. Using a magnetic finger, remove the ball from the rear output shaft.
  
  Fig 4: Locating Extension Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHAFT HEAD NO. 2
1. Using a pin punch and hammer, tap out the slotted pin from the high and low fork shaft.
2. Remove the shaft head No. 2.
  
  Fig 5: Tapping Out Slotted Pin From High & Low Bank Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR CASE
Remove the 12 bolts, 2 clamps and rear case.

NOTE: If necessary, tap the rear case with a plastic hammer to remove it.

Fig 6: Removing Rear Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STRAIGHT SCREW PLUG, SPRING AND BALL
1. Using a hexagon wrench, remove the 2 straight screw plugs.
2. Using a magnetic finger, remove the spring and ball.
  
  Fig 7: Removing Straight Screw Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 GEAR SHIFT FORK AND HIGH AND LOW SHIFT FORK SHAFT
1. Remove 2 screwdrivers and a hammer, tap out the snap ring.
  
  Fig 8: Tapping Out Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, tap out the slotted spring pin from the No. 2 rear shift fork.
  
  Fig 9: Tapping Out Slotted Spring Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the No. 2 gear shift fork and high and low shift fork shaft.
  
  Fig 10: Removing No. 2 Gear Shaft Fork & High & Low Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK SHAFT
1. Using 2 screwdrivers and a hammer, remove the 3 snap rings from the gear shift fork shaft.
  
  Fig 11: Removing Snap Rings From Gear Shift Bank Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a hexagon wrench, remove the 2 straight screw plugs, springs and balls from the No. 1 gear shift fork and center different. lock fork.
  
  Fig 12: Removing Straight Screw Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the bolt and shift shaft stopper.
  
  Fig 13: Removing Shift Shaft Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Rotate the slit portion of the gear shift fork shaft to the No. 2 shift interlock pin and remove it.
  
  Fig 14: Removing Inter Lock Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a magnetic finger, remove the 2 No. 2 shift interlock pins from the No. 1 gear shift fork and center different. lock fork.
  
  Fig 15: Removing No. 2 Shift Interlock Pins From No. 1 Gear Shift Bank & Center Different. Lock Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR OUTPUT SHAFT ASSEMBLY, NO. 1 GEAR SHIFT FORK, CENTER DIFFERENT. LOCK FORK, DRIVEN SPROCKET ASSEMBLY AND FRONT DRIVE CHAIN
1. Using 2 screwdrivers and a hammer, tap out the 2 snap rings from the gear shift fork shaft of the actuator assembly.
2. Using a snap ring expander, remove the output shaft snap ring.
  
  Fig 16: Tapping Out Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Mount the rear case in a vise, as shown.
4. Using the plastic hammer, carefully tap the case, and remove the rear output shaft assembly with the No. 1 gear shift fork, center different. lock fork, driven sprocket assembly and front drive chain.
  
  Fig 17: Removing Rear Output Shaft Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the front driven chain, driven sprocket assembly, center different. lock fork and No. 1 gear shift fork from the rear output shaft assembly.
REMOVE ACTUATOR ASSEMBLY
1. Remove the 3 bolts, clamp and actuator assembly.
2. Remove the O-ring, No. 1 and No. 2 4WD position switches with the 2 gaskets from the actuator assembly.
  
  Fig 18: Removing Actuator Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL SEPARATOR AND MAGNET
1. Remove the 3 bolts and oil separator.
2. Remove the magnet from the front case.
REMOVE OIL PUMP BODY ASSEMBLY
Remove the 3 bolts and oil pump body assembly.

Fig 19: Locating Oil Pump Body Assy Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PUMP GEAR FROM FRONT CASE

Fig 20: Removing Oil Pump Gear From Front Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY
1. Using a snap ring expander, remove the low planetary gear bearing snap ring.
2. Pull out the planetary gear assembly with the input shaft assembly.
  
  Fig 21: Removing Low Planetary Gear Assy With Input Shaft Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOW PLANETARY GEAR SPLINE PIECE
1. Using a screwdriver, remove the low planetary gear snap ring.
2. Remove the low planetary gear spline piece.
  
  Fig 22: Removing Low Planetary Gear Spline Piece
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT NEEDLE ROLLER BEARING FROM INPUT SHAFT

Fig 23: Removing Output Shaft Needle Roller Bearing From Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT GEAR STOPPER, LOW PLANETARY CARRIER THRUST WASHER AND INPUT GEAR STOPPER BALL
1. Using a snap ring expander, remove the input gear stopper snap ring.
2. Remove the input gear stopper, low planetary carrier thrust washer and input gear stopper ball.
  
  Fig 24: Removing Input Gear Stopper, Low Planetary Carrier Thrust Washer & Input Gear Stopper Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT ASSEMBLY, LOW PLANETARY GEAR BEARING AND NO. 2 THRUST BEARING RACE

Fig 25: Removing Input Shaft Assy Low Planetary Gear Bearing & No. 2 Thrust Bearing Rase
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PLANETARY RING GEAR
1. Using a screwdriver, remove the low planetary ring gear hole snap ring.
2. Remove the head screw plug, spring and pin.
  
  Fig 26: Removing Head Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the low planetary ring gear.
  
  Fig 27: Removing Low Planetary Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002