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Transfer Assembly: Reassembly

WARNING: This page is about a different variant/trim than selected.
NOTE: Coat all of the sliding and rotating surface with gear oil before reassembly.
  1. INSTALL LOW PLANETARY RING GEAR 
    1. Install the low planetary ring gear.
      NOTE: Make sure to install the low planetary ring gear in the correct direction.
    2. Install the pin and spring.
    3. Apply sealant to the head screw plug threads.
      1. Sealant: 
      2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    4. Install the head screw plug.
      1. Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 
      Fig 1: Installing Low Planetary Ring Gear
      G02927560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a screwdriver, install the low planetary ring gear hole snap ring.
    NOTE: Be sure the end gap of the snap ring is not aligned with the upper side of the case.
  2. INSTALL LOW PLANETARY GEAR BEARING, NO. 2 THRUST BEARING RACE AND INPUT SHAFT ASSEMBLY 
    Fig 2: Installing Low Planetary Ring Gear Hole Snap Ring
    G02927561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL INPUT GEAR STOPPER BALL, LOW PLANETARY CARRIER THRUST WASHER AND INPUT GEAR STOPPER 
    1. Install the input gear stopper ball, low planetary carrier thrust washer and input gear stopper.
      Fig 3: Installing Input Gear Stopper Ball, Low Planetary Carrier Thrust Washer & Input Gear Stopper
      G02927562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a input gear stopper snap ring that allows 0.05 - 0.15 mm (0.0020 - 0.0059 in.) axial play.
      Fig 4: Selecting Input Gear Stopper Snap Ring
      G02927563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS REFERENCE

      Mark Thickness mm (in.)
      A 2.10 - 2.15 (0.0827 - 0.0846)
      B 2.15 - 2.20 (0.0846 - 00866)
      C 2.20 - 2.25 (0.0866 - 0.0886)
      D 2.25 - 2.30 (0.0886 - 0.0906)
      E 2.30 - 2.35 (0.0906 - 0.0925)
      F 2.35 - 2.40 (0.0925 - 0.0945)
      G 2.40 - 2.45 (0.0945 - 0.0965)
      H 2.45 - 2.50 (0.0965 - 0.0984)
      J 2.50 - 2.55 (0.0984 - 0.1004)
      K 2.55 - 2.60 (0.1004 - 0.1024)
      L 2.60 - 2.65 (0.1024 - 0.1043)
      M 2.65 - 2.70 (0.1043 - 0.1063)
      N 2.70 - 2.75 (0.1063 - 0.1083)
      P 2.75 - 2.80 (0.1083 - 0.1102)
      Q 2.80 - 2.85 (0.1102 - 0.1122)
      R 2.85 - 2.90 (0.1122 - 0.1142)
      S 2.90 - 2.95 (0.1142 - 0.1161)
      T 2.95 - 3.00 (0.1161 - 0.1181)
      U 3.00 - 3.05 (0.1181 - 0.1201)
    3. Using a snap ring expander, install a new input gear stopper snap ring.
  4. INSTALL OUTPUT SHAFT NEEDLE ROLLER BEARING TO INPUT SHAFT 
  5. INSTALL LOW PLANETARY GEAR SPLINE PIECE 
    1. Install the low planetary gear spline piece.
    2. Using a screwdriver, install the low planetary gear snap ring.
    NOTE: Be sure the end gap of the snap ring is not aligned with cutout portion of the low planetary gear
  6. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY 
    1. Install the low planetary gear assembly with the input shaft assembly to the front case.
      NOTE: If necessary, heat the front case to about 50 - 80 °C (122 - 176 °F).
      Fig 5: Installing Low Planetary Gear Shaft Ring
      G02927564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install the low planetary gear bearing snap ring.
    NOTE: Check that the low planetary gear assembly and input shaft assembly turn lightly.
  7. INSTALL OIL PUMP GEAR TO FRONT CASE 
  8. INSTALL OIL PUMP BODY ASSEMBLY 

    Install the oil pump body assembly with the 3 bolts.

    1. Torque: 7.5 N.m (80 kgf.cm, 69 in..lbf) 
  9. INSTALL MAGNET AND OIL SEPARATOR 
    1. Install the magnet to the front case.
    2. Install the oil separator with the 3 bolts.
    1. Torque: 7.5 N.m (80 kgf.cm, 69 in..lbf) 
  10. INSTALL ACTUATOR ASSEMBLY 
    1. Install a new O-ring, No. 1 and No. 2 4WD position switches with 2 new gaskets.
      1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 
    2. Install the actuator assembly and clamp with the 3 bolts.
    1. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 
  11. INSTALL REAR OUTPUT SHAFT ASSEMBLY, NO. 1 GEAR SHIFT FORK, CENTER DIFFERENT. LOCK FORK, DRIVEN SPROCKET ASSEMBLY AND FRONT DRIVE CHAIN 
    1. Install the No. 1 gear shift fork, center different. lock fork, driven sprocket assembly and front drive chain to the rear output shaft assembly.
      NOTE: Make sure to install the forks in the correct direction.
    2. Install the rear output shaft assembly with the driven sprocket assembly to the rear case.
      NOTE: Do not let the clutch sleeve and shifting key drop.
      NOTE: If necessary, heat the rear case to about 50 - 80 °C (122 - 176 °F).
    3. Using a snap ring expander, install the output shaft snap ring.
      NOTE: Check that the rear output shaft assembly and driven sprocket turn lightly.
      Fig 6: Installing No. 1 Gear Shift Fork, Center Different. Lock Fork, Driven Sprocket Assy & Front Drive Chain To Rear Output Shaft Assy
      G02927565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a screwdriver and hammer, drive in the 2 snap rings to the gear shift fork shaft of the actuator assembly.
      Fig 7: Drive In Snap Rings To Gear Shift Fork Shaft Of Actuation Assy
      G02927566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL GEAR SHIFT FORK SHAFT 
    1. Using a magnetic finger, install the 2 No. 2 shift interlock pins top the No. 1 gear shift fork and center different. lock fork.
      Fig 8: Installing No. 2 Shaft Interlock Pin Stop No. 1 Gear Shift Fork
      G02927567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the slit portion of the gear shift fork shaft with it facing No. 2 shaft interlock pin and rotate the gear shift fork shaft, as shown in the illustration.
      Fig 9: Installing Slit Portion Of Gear Shift Fork Shaft
      G02927568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the shift shaft stopper with the bolt.
      1. Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 
      Fig 10: Installing Shift Shaft Stopper With Bolt
      G02927569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 springs and balls to the No. 1 gear shift fork and center different. lock fork.
    5. Apply sealant to the straight screw plug threads.
      1. Sealant: 
      2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    6. Using a hexagon wrench, install the 2 straight screw plugs to the No. 1 gear shift fork and center different. lock fork.
      1. Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 
      Fig 11: Applying Sealant To Straight Screw Plug Threads
      G02927570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a screwdriver and hammer, drive in the 3 snap rings to the gear shift fork shaft of the actuator assembly.
      Fig 12: Drive In Snap Rings To Gear Shift Fork Shaft
      G02927571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL HIGH AND LOW SHIFT FORK SHAFT, AND NO. 2 GEAR SHIFT FORK 
    1. Install the high and low shift fork shaft and No. 2 gear shift fork.
      NOTE: Make sure to install the No. 2 gear shift fork in the correct direction.
      Fig 13: Installing High & Low Shift Fork Shift
      G02927572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a pin punch and hammer, drive in the slotted spring pin to the No. 2 gear shift 
      Fig 14: Drive In Slotted Spring Pin To No. 2 Gear Shift Fork
      G02927573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL STRAIGHT SCREW PLUG, SPRING AND BALL 
    1. Install the ball and spring.
    2. Apply sealant to the straight screw plug threads.
      1. Sealant: 
      2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    3. Using a hexagon wrench, install the 2 straight screw plugs.
      1. Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 
    4. Using a screwdriver and hammer, drive in the snap ring to the gear shift fork shaft.
      Fig 15: Installing Ball & Spring
      G02927574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 16: Drive In Snap Ring To Gear Shift Bank Shaft
      G02927575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL REAR CASE 
    1. Apply FIPG to the rear case, as shown.
      1. FIPG: 
      2. Part No. 08826-00090, THREE BOND 1281 or equivalent 
    2. Assemble the rear case and 2 clamps with the 12 bolts.
      1. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 
      Fig 17: Applying FIPG To Rear Case
      G02927576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL SHIFT HEAD NO. 2 
    1. Install the shift head No. 2.
    2. Using a pin punch and hammer, drive in the slotted spring pin to the shift head No. 2.
  17. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR AND OUTPUT SHAFT WASHER 
    1. Install the ball on the rear output shaft.
    2. Install the vehicle speed sensor drive gear and 2 output shaft washers.
      Fig 18: Installing Shift Head No. 2
      G02927577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL EXTENSION HOUSING 
    1. Apply FIPG to the extension housing, as shown.
      1. FIPG: 
      2. Part No. 08826-00090, THREE BOND 1281 or equivalent 
    2. Apply sealant to the bolt threads.
      1. Sealant: 
      2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    3. Install the extension housing with the 5 bolts.
    1. Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 
    Fig 19: Applying FIPG To Extension Housing
    G02927578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FRONT COMPANION FLANGE 
    1. Install the front companion flange to the input shaft assembly.
    2. Using SST to hold the front companion flange, install a new front companion flange lock nut.
      1. SST 09330-00021 
      1. Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf) 
    3. Stake the front companion flange lock nut.
      Fig 20: Installing Front Companion Flange
      G02927579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL REAR COMPANION FLANGE 

    Install the rear companion flange in the same way as the front companion flange.

  21. INSTALL TRANSFER UPPER COVER 

    Install a new oil deflector and the transfer upper cover with the 4 bolts.

    1. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 
    Fig 21: Applying FIPG To Front Bearing Retainer
    G02927580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL FRONT BEARING RETAINER 
    1. Apply FIPG to the front bearing retainer, as shown.
      1. FIPG: 
      2. Part No. 08826-00090, THREE BOND 1281 or equivalent 
    2. Apply sealant to the bolt threads.
      1. Sealant: 
      2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    3. Install the front bearing retainer with the 5 bolts.
      1. Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 
  23. INSTALL L4 POSITION SWITCH, NEUTRAL POSITION SWITCH AND STRAIGHT SCREW PLUG WITH 3 NEW GASKETS 
    1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 
  24. INSTALL VEHICLE SPEED SENSOR ASSEMBLY 
    1. Install the vehicle speed sensor driven gear to the vehicle speed sensor assembly with the clip.
    2. Install a new O-ring to the vehicle speed sensor assembly.
    3. Install the vehicle speed sensor assembly with the bolt.
      1. Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 
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