Section 2 (Transfer Case): Overhaul

AUTOMATIC TRANSMISSION

COMPONENTS: See COMPONENTS

TRANSFER COMPONENTS: See COMPONENTS 

1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See )  REPLACEMENT 
2. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (See  REPLACEMENT  ) 
3. REMOVE TRANSFER CASE NO. 1 PLUG 
   1. Remove the No. 1 plug.
   2. Remove the gasket from the plug.
   Fig 1: Removing Transfer Case Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE TRANSFER CASE NO. 2 PLUG 
   1. Remove the No. 2 plug.
   2. Remove the gasket from the plug.
5. REMOVE TRANSFER DRAIN PLUG 
   1. Remove the drain plug and drain the oil.
   2. Remove the gasket from the drain plug.
6. REMOVE TRANSFER ASSY 
   1. Remove the 2 bolts and 6 nuts.
   2. Using a plastic hammer, drive out the transfer assy from the transaxle assy.
   Fig 2: Removing Transfer Assy From Transaxle Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Disconnect the transfer assy from the transaxle assy without tilting.
   • When moving the transfer assy, do not hold the oil seal parts by both sides of the assy.
   Fig 3: Removing Transfer Cover Gasket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE TRANSFER COVER GASKET 
   1. Remove the gasket from the transfer assy.
8. REMOVE TRANSFER CASE BREATHER PLUG 
   1. Using a screwdriver and a hammer, remove the breather plug from the case cover.
   Fig 4: Removing Transfer Case Breather Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE TRANSFER CASE COVER NO. 1 
   1. Remove the 8 bolts.
      Fig 5: Removing Transfer Case Cover No. 1

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a brass bar and a hammer, remove the case cover from the case.
   NOTE: Be careful not to damage the mating surfaces of the case and cover.
   Fig 6: Removing Case Cover From Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE BREATHER OIL DEFLECTOR 
    1. Remove the bolt and breather oil deflector from the case cover.
    Fig 7: Removing Breather Oil Deflector

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE TRANSFER DYNAMIC DAMPER 
    1. Remove the 3 bolts and the dynamic damper from the extension housing.
    Fig 8: Removing Transfer Dynamic Damper

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 4 transfer case straight pins from the transfer case.
13. REMOVE TRANSFER & TRANSAXLE SETTING STUD BOLT 
    1. Remove the 4 stud bolts.
14. FIX TRANSFER ASSY 
    1. Fix the transfer assy to the overhaul attachment.
15. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR 
    1. Using a plastic hammer, remove the dust deflector from the extension housing.
    Fig 9: Removing Transfer Extension Housing Dust Deflector

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST, remove the oil seal from the extension housing.

       SST 09308-00010

    NOTE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.
    Fig 10: Removing Transfer Extension Housing Type T Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY 
    1. Remove the 4 bolts.
       Fig 11: Removing Transfer Extension Housing Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the extension housing from the case.
    Fig 12: Removing Extension Housing From Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. INSPECT PRELOAD 
    1. Using SST and a torque wrench, check the initial torque within the backlash range.

       SST 09326-2001 1

       Torque: 0.9 - 1.4 N.m (9 - 14 kgf.cm, 8.0 - 12.4 in. lbf) 

       NOTE: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
       Fig 13: Checking Preload

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a torque wrench, check the initial torque with the driven pinion being contact with the ring gear face.

       SST 09326-2001 1

       Torque: Driven pinion preload 

       +0.15 - 0.30 N.m (+1.6 - 3.1 kgf.cm, +1.3 - 2.7 in. lbf) 

       NOTE: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
19. INSPECT BACKLASH 
    1. Set the dial gauge perpendicular to the tooth face of the ring gear, fix the driven pinion and check the backlash while moving the gear.

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

    NOTE: Check it at 3 points or more on the gear periphery.
    Fig 14: Checking Backlash

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION 
    1. Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate it several times.
       NOTE: Check the tooth contact on the ring gear at 4 places or more.
       Fig 15: Applying Red Lead Primer On Ring Gear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Proper washer location is shown.
    Fig 16: Proper Teeth Contact Pattern

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE CTR DIFFERENTIAL LOCK SLEEVE 
    1. Using a snap ring pliers, remove the shaft snap ring.
       Fig 17: Removing Shaft Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the center differential lock sleeve.

       SST 09308-00010

    Fig 18: Removing Center Differential Lock Sleeve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. REMOVE O-RING 
    1. Using a screwdriver with the tip protected by taping, remove the O-ring from the center differential lock sleeve.
    NOTE: Be careful not to damage the lock sleeve's groove for the O-ring.
    Fig 19: Removing O-Ring From Center Differential Lock Sleeve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. REMOVE TRANSFER CASE OIL SEAL 
    1. Using SST, remove the oil seal from the case.

    SST 09308-00010

    NOTE: Be careful not to damage the oil-seal-fitted surface of the case.
    Fig 20: Removing Transfer Case Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST, remove the oil seal from the right bearing retainer.

       SST 09308-00010

    NOTE: Be careful not to damage the oil-seal-fitted surface of the retainer.
    Fig 21: Removing Transfer RH Bearing Retainer Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY 
    1. Remove the 7 bolts from the right bearing retainer.
       Fig 22: Removing Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver and a hammer, make a clearance between the right bearing retainer and the transfer case.
       Fig 23: Identifying Clearance Between Right Bearing Retainer & Transfer Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the right bearing retainer from the transfer case.

       SST 09520-10021

    Fig 24: Removing Right Bearing Retainer From Transfer Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. REMOVE TRANSFER RH BEARING RETAINER O-RING 
    1. Using a screwdriver with the tip protected by taping, remove the 2 O-rings from the right bearing retainer.
    NOTE: Be careful not to damage the retainer's groove for the O-ring.
    Fig 25: Removing Transfer RH Bearing Retainer O-Ring

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Hold the right bearing retainer in a vise.
    2. Using SST, remove the outer race, washer and oil seal from the right bearing retainer.

       SST 09308-00010

    NOTE: Be careful not to damage the oil-seal-fitted surface of the retainer.
    Fig 26: Removing Center Differential Case Tapered Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. REMOVE SIDE GEAR SHAFT HOLDER BEARING 
    1. Using a snap ring pliers, remove the side gear shaft holder hole snap ring.
    2. Remove the side gear shaft holder bearing from the right bearing retainer.
    Fig 27: Removing Side Gear Shaft Holder Hole Snap Ring

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. REMOVE TRANSFER RING GEAR MOUNTING CASE 
    1. Remove the ring gear mounting case assy from the case.
    Fig 28: Removing Transfer Ring Gear Mounting Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. RH side:

       Using SST, remove the inner race of the center differential case tapered roller bearing from the ring gear mounting case assy.

       SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00420)

       Fig 29: Removing Center Differential Case Tapered Roller Bearing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Apply grease to the screw thread and the tip of the SST before use.
       NOTE: When the roller comes off due to deformation of the gauge, completely remove the roller and take away remaining inner races of the center differential case tapered roller bearing from the ring gear mounting case assy.

       SST 09950-00020, 09950- 00030, 09950- 6001 0 (09951-00430)

       NOTE: Apply grease to the screw thread and the tip of the SST before use.
       Fig 30: Removing Roller & Remaining Inner Races

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. LH side:

       Using SST, remove the inner race of the center differential case tapered roller bearing from the ring gear mounting case assy.

       SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)

       Fig 31: Removing Inner Race Of Center Differential Case Tapered Roller Bearing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Apply grease to the screw thread and the tip of the SST before use.
       NOTE: When the roller comes off due to deformation of the gauge, completely remove the roller and take away remaining inner races of the center differential case tapered roller bearing from the ring gear mounting case assy.

       SST 09950-00020, 09950- 00030, 09950- 6001 0 (09951-00360)

       NOTE: Apply grease to the screw thread and the tip of the SST before use.
    Fig 32: Removing Roller & Remaining Inner Races

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. REMOVE RING GEAR 
    1. Put matchmarks on the ring gear mounting case assy and the ring gear.
    2. Remove the 12 bolts.
       Fig 33: Identifying Matchmarks On Ring Gear Mounting Case Assy & Ring Gear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, remove the ring gear by tapping around its periphery.
    NOTE: Do not damage the tooth face of the ring gear.
    Fig 34: Removing Ring Gear By Tapping Around Its Periphery

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. INSPECT RUNOUT OF TRANSFER RING GEAR MOUNTING CASE 
    1. Using a dial indicator, check for the ring gear mounting case runout.

       Maximum runout: 0.03 mm (0.0012 in.) 

    Fig 35: Inspecting Runout Of Transfer Ring Gear Mounting Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. REMOVE DRIVEN PINION 
    1. Using SST and a hammer, unstake the staked part of the gear nut.

       SST 09930-00010

       Fig 36: Unstaking Staked Part Of Gear Nut

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the gear nut.

       SST 09326-2001 1, 09556-16030

       Fig 37: Removing Gear Nut

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a press, remove the driven pinion, bearing inner rear race and bearing spacer.
    NOTE:

    • Put a shop rug to prevent the driven pinion from dropping.
    • Place something like wood blocks under the case to keep it level.
    Fig 38: Removing Driven Pinion, Bearing Inner Rear Race & Bearing Spacer

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
34. REMOVE TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST and a press, remove the inner race from the driven pinion.

       SST 09950-00020

    Fig 39: Removing Transfer Driven Pinion Front Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
35. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using a brass bar and a hammer, lightly strike the outer race at 2 points to remove it from the case.
36. REMOVE RING GEAR MOUNTING CASE PLATE WASHER 
    Fig 40: Removing Ring Gear Mounting Case Plate Washer

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
37. REMOVE TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using a brass bar and a hammer, lightly strike the outer race at 2 points to remove it from the case.
38. REMOVE TRANSFER OUTPUT WASHER 
    Fig 41: Removing Transfer Driven Pinion Front Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
39. REMOVE TRANSFER DRIVEN PINION REAR BEARING 
    1. Using a brass bar and a hammer, lightly strike the outer race at 2 points to remove it from the case.
    Fig 42: Removing Transfer Driven Pinion Rear Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
40. INSTALL TRANSFER DRIVEN PINION REAR BEARING 
    1. Using SST and a press, install the outer race to the case.

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

    NOTE: Place something like wood blocks under the case to keep it level.
    Fig 43: Installing Transfer Driven Pinion Rear Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
41. INSTALL TRANSFER OUTPUT WASHER 
    1. Install the washer to the case.
    NOTE: Reuse the washer used before disassembly.
42. INSTALL TRANSFER DRIVEN PINION FRONT BEARING 
    1. Install the outer race to the case with SST, a bolt and a nut.

       SST 09950-60010 (09951-00750, 09951-00770, 09951-00810), 09316-60011 (09316-00061)

    Fig 44: Installing Transfer Driven Pinion Front Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
43. INSTALL RING GEAR MOUNTING CASE PLATE WASHER 
    1. Install the washer to the case.
    NOTE: Reuse the washer used before disassembly.
44. INSTALL w 
    1. Using SST and a press, install the outer race to the case.

       SST 09950-70010 (09951-07200), 09316-60011 (09316-00021)

    Fig 45: Installing Transfer Driven Pinion Front Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
45. INSTALL TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST and a press, install the inner race to the driven pinion.

       SST 09316-6001 1 (09316-00041)

    Fig 46: Installing Transfer Driven Pinion Front Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
46. INSTALL DRIVEN PINION 
    1. Install the driven pinion to the case.
       Fig 47: Installing Driven Pinion To Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new bearing spacer and a new bearing rear to the driven pinion.
       Fig 48: Installing Bearing Spacer & Bearing Rear To Driven Pinion

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, tighten a new gear nut with a standard torque.

       SST 09326-2001 1, 09556-16030

       Torque: 277 - 378 N.m (2,820 - 3,853 kgf.cm, 204 - 279 ft.lbf) 

    NOTE: Do not stake the gear nut.
    NOTE: Use a torque wrench with a fulcrum length of 750 mm (29.53 in.)
    Fig 49: Tightening Gear Nut With Standard Torque

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
47. INSPECT AND ADJUST DRIVEN PINION PRELOAD 
    1. Using SST and a torque wrench, measure the initial torque of the driven pinion.

       SST 09326-2001 1

       Preload (at starting): 

       New bearing: 

       1.1 - 1.6 N.m (11 - 16 kgf.cm, 9.7 - 14.2 in. lbf) 

       Used bearing: 

       0.9 - 1.4 N.m (9 - 14 kgf.cm, 8.0 - 12.4 in. lbf) 

       Fig 50: Inspecting & Adjusting Driven Pinion Preload

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
       NOTE: Measure it after rotating the bearing in both clockwise and counter clockwise directions to make it fit.
    2. If the preload is too large, replace the bearing spacer with new one.
    3. If the preload is too small, repeatedly adjust the preload by tightening the lock nut 5 - 10 degrees at a time until the standard value is obtained.
    4. If the preload is insufficient even though the tightening torque of the lock nut exceeds the maximum of the standard value, loosen the lock nut and apply gear oil SAE 90 (GL-5) to the lock nut and the screw thread and the base of the driven pinion. And then repeat the preceding operation. If the tightening torque is smaller than the standard, replace the bearing spacer with new one and adjust it.

       SST 09326-2001 1, 09556-16030

       Torque: 378 N.m (3,855 kgf.cm, 279 ft.lbf) 

48. INSTALL RING GEAR 
    1. Heat the ring gear in boiling water to 90 -100 °C (194 - 212 °F).
    2. Completely remove grease and moisture on the mating surfaces of the ring gear and the ring gear mounting case.
       Fig 51: Heating Ring Gear In Boiling Water

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the matchmarks on the ring gear and ring gear mounting case and quickly assemble them.
    4. Tighten the 12 bolts.

       Torque: 78 N.m (790 kgf.cm, 57 ft.lbf) 

    Fig 52: Aligning Matchmarks On Ring Gear & Ring Gear Mounting Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    • Tighten the bolts in diagonal order in splitting several times.
    • After the ring gear has well cooled down, tighten the bolts.
    • Make paint marks, etc, do the procedure while checking the bolts retightened.
49. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. RH side:

       Using SST and a press, install the inner race of the center differential case tapered roller bearing to the ring gear mounting case assy.

       SST 09506-35010, 09950-60010 (09951-00430)

       NOTE: When replacing the inner race, replace the outer race, too.
       Fig 53: Installing Center Differential Case Tapered Roller Bearing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. LH side:

       Using SST and a press, install the inner race of the center differential case tapered roller bearing to the ring gear mounting case assy.

       SST 09223-00010

       NOTE: When replacing the inner race, replace the outer race, too.
    Fig 54: Installing Inner Race Of Center Differential Case Tapered Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
50. INSTALL TRANSFER RING GEAR MOUNTING CASE 
    1. Install the ring gear mounting case assy to the case.
    NOTE: Damage to the spline, bearing's rotating surface and gear face may cause decrease in their strength. Care should be taken at the time of installation.
51. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO. 2 
    NOTE: Reuse the washer used before disassembly.
    Fig 55: Installing Ring Gear Mounting Case Assy To Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
52. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using SST and a press, install the outer race to the right bearing retainer.

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

    Fig 56: Installing Center Differential Case Tapered Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
53. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY 
    1. Place the transfer with the face where the right bearing retainer is to be installed facing up.
    2. Center-align the ring gear mounting case assy and the case.
       Fig 57: Installing Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Insert the SST into the right bearing retainer.

       SST 09387-00090

       NOTE: Insert SST straight in order not to damage the oil seal lip.
       Fig 58: Inserting SST Into Right Bearing Retainer

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Insert the right bearing retainer together with the SST into the case.
       NOTE: Hard interference between the case and the retainer, and between the center differential control coupling assy and SST should be carefully avoided.
       NOTE: If the retainer cannot be inserted, tap it in with a plastic hammer.
       Fig 59: Inserting Right Bearing Retainer Into Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. After inserting the right bearing retainer into the case, remove the SST.
       Fig 60: Removing SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the 7 bolts.

       Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

    Fig 61: Tightening Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
54. INSPECT BACKLASH 
    1. Set the dial gauge perpendicular to the ring gear face, fix the driven pinion, and check the backlash by moving the ring gear.

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

       Fig 62: Inspecting Backlash

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Measure it at 3 points or more on the ring gear periphery.
    2. If the measured value is out of the standard, select a proper washer for the center differential case tapered roller bearing on the LH side from the table below and install it to obtain the standard value.
       WASHER SPECIFICATIONS
       
       

       Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
       AA	2.07(0.0814)	AB	2.10(0.0826)	AC	2.13(0.0838)
       BA	2.16(0.0850)	BB	2.19(0.0862)	BC	2.22 (0.0874)
       CA	2.25 (0.0885)	CB	2.28 (0.0897)	CC	2.31 (0.0909)
       DA	2.34(0.0921)	DB	2.37 (0.0933)	DC	2.40 (0.0944)
       EA	2.43 (0.0956)	EB	2.46 (0.0968)	EC	2.49 (0.0980)
       FA	2.52 (0.0992)	FB	2.55(0.1003)	FC	2.58(0.1015)
       GA	2.61 (0.1027)	GB	2.64(0.1039)	GC	2.67(0.1051)
       HA	2.70(0.1062)	HB	2.73(0.1074)	HC	2.76(0.1086)
       JA	2.79(0.1098)	JB	2.82(0.1110)	JC	2.85(0.1122)
       KA	2.88(0.1133)	KB	2.91 (0.1145)	KC	2.94(0.1157)
       LA	2.97(0.1169)	LB	3.00(0.1181)	-	-

       NOTE: When the backlash is larger or smaller than the standard, select a thinner or thicker washer respectively.
    3. Proper washer location is shown.
    Fig 63: Identifying Washer Location

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
55. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION 
    1. Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate it several times.
       NOTE: Check the tooth contact on the ring gear at 4 places or more.
       Fig 64: Applying Red Lead Primer On Ring Gear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Observe the pattern shown by red lead primer.
       Fig 65: Proper Teeth Contact Pattern

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. In the case of faulty tooth contact, select a washer for the driven pinion bearing front side from the following table and reinstall it.
       NOTE: If the washer thickness is changed, the backlash will be also changed.
       WASHER SPECIFICATIONS
       
       

       Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
       AA	1.20 (0.0472)	AC	1.22 (0.0480)	BB	1.24 (0.0488)
       CA	1.26 (0.0496)	CC	1.28 (0.0503)	DB	1.30(0.0511)
       EA	1.32(0.0519)	EC	1.34 (0.0527)	FB	1.36 (0.0535)
       GA	1.38 (0.0543)	GC	1.40(0.0551)	HB	1.42 (0.0559)
       JA	1.44 (0.0566)	JC	1.46 (0.0574)	KB	1.48 (0.0582)
       LA	1.50 (0.0590)	LC	1.52 (0.0598)	MB	1.54 (0.0606)
       NA	1.56(0.0614)	NC	1.58 (0.0622)	PB	1.60(0.0629)
       QA	1.62(0.0637)	QC	1.64(0.0645)	-	-

    4. The location of the washer for tooth contact adjustment is shown.
    Fig 66: Identifying Washer Location

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
56. ADJUST TOTAL PRELOAD 
    1. Using SST and a torque wrench, measure the initial torque with the driven pinion being contact with the ring gear face.

       SST 09326-2001 1

       Fig 67: Adjusting Total Preload

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Torque: 

       New bearing: 

       Driven pinion preload +0.2 - 0.4 N.m (+2.3 - 3.9 kgf.cm, +1.8 - 3.5 in. lbf) 

       Used bearing: 

       Driven pinion preload +0.15 - 0.30 N.m (+1.6 - 3.1 kgf.cm, +1.3 - 2.7 in. lbf) 

       NOTE: Before measurement, rotate the bearing in both directions several times to make it fit.
       NOTE: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
    2. If the value is out of the standard range, select the washer for the center differential case tapered roller bearing RH side from the following table and reinstall it.
       WASHER SPECIFICATIONS
       
       

       Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
       AA	1.47 (0.0578)	AB	1.50 (0.0590)	AC	1.53 (0.0602)
       BA	1.56(0.0614)	BB	1.59 (0.0625)	BC	1.62(0.0637)
       CA	1.65(0.0649)	CB	1.68(0.0661)	CC	1.71 (0.0673)
       DA	1.74 (0.0685)	DB	1.77 (0.0696)	DC	1.80 (0.0708)
       EA	1.83 (0.0720)	EB	1.86 (0.0732)	EC	1.89 (0.0744)
       FA	1.92 (0.0755)	FB	1.95 (0.0767)	FC	1.98 (0.0779)
       GA	2.01 (0.0790)	GB	2.04 (0.0803)	GC	2.07(0.0814)
       HA	2.10(0.0826)	HB	2.13(0.0838)	HC	2.16(0.0850)
       JA	2.19(0.0862)	JB	2.22 (0.0874)	JC	2.25 (0.0885)
       KA	2.28 (0.0897)	KB	2.31 (0.0909)	KC	2.34(0.0921)
       LA	2.37 (0.0933)	LB	2.40 (0.0944)	LC	2.43 (0.0956)
       MA	2.46 (0.0968)	MB	2.49 (0.0980)	MC	2.52 (0.0992)
       NA	2.55(0.1003)	NB	2.58(0.1015)	-	-

    3. The location of the washer for preload adjustment is shown.
       Fig 68: Identifying Washer Location

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a chisel, stake the gear nut.
    Fig 69: Staking Gear Nut

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
57. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY 
    1. Remove the 7 bolts from the right bearing retainer.
       Fig 70: Removing Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver and a hammer, make a clearance between the right bearing retainer and the transfer case.
       Fig 71: Identifying Clearance Between Right Bearing Retainer & Transfer Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the right bearing retainer from the transfer case.

       SST 09520-10021

    Fig 72: Removing Right Bearing Retainer From Transfer Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
58. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Hold the right bearing retainer in a vise.
    2. Using SST, remove the outer race and washer from the right bearing retainer.

       SST 09308-00010

    Fig 73: Removing Center Differential Case Tapered Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
59. INSTALL SIDE GEAR SHAFT HOLDER BEARING 
    1. Install the side gear shaft holder bearing to the right bearing retainer.
    2. Using a snap ring pliers, install the side gear shaft holder hole snap ring.
    NOTE: Check that the snap ring is fit in the groove of the retainer.
    Fig 74: Installing Side Gear Shaft Holder Hole Snap Ring

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
60. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST and a press, install the oil seal to the right bearing retainer.
       NOTE: Carefully press-fit so that the oil seal will not be tilted.
    2. Apply small amount of MP grease No. 2 to the oil seal lip.

       SST 09950-60010 (09951-00360, 09951-00540, 09952-06010), 09950-70010 (09951-07150)

    Fig 75: Installing Transfer RH Bearing Retainer Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
61. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO. 2 
    1. Install the selected ring gear mounting washer to the right bearing retainer.
62. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using SST and a press, install the outer race to the right bearing retainer.

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

    Fig 76: Installing Center Differential Case Tapered Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
63. INSTALL O-RING 
    1. Apply hypoid gear oil to a new O-ring.
    2. Install the 2 O-rings to the right bearing retainer.
    NOTE: Be careful not to twist the O-ring and fit it into the retainer's groove properly.
    Fig 77: Installing O-Rings To Right Bearing Retainer

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
64. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY 
    1. Place the transfer with the face where the right bearing retainer is to be installed facing up.
    2. Center-align the center differential control coupling assy and the case.
       Fig 78: Installing Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Insert SST into the right bearing retainer.

       SST 09387-00090

       NOTE: Insert SST straight in order not to damage the oil seal.
       Fig 79: Inserting SST Into Right Bearing Retainer

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Insert the right bearing retainer together with SST into the case.
       NOTE:

       • Prevent hard interference between the case and the retainer, and between the SST and the center differential control coupling assy.
       • Carefully check for damage and incorrect fitting of the retainer's O-ring.
       NOTE: If the retainer cannot be inserted into the case, tap it in with a plastic hammer.
       Fig 80: Inserting Right Bearing Retainer Into Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. After inserting the right bearing retainer into the case, remove the SST.
       Fig 81: Removing SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the 7 bolts.

       Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

    Fig 82: Tightening Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
65. INSPECT TOTAL PRELOAD 
    1. Using SST and a torque wrench, measure the initial torque with the driven pinion being contact with the ring gear face.

       SST 09326-2001 1

       Fig 83: Inspecting Total Preload

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Torque: 

       New bearing: 

       Driven pinion preload +0.2 - 0.4 N.m 

       (+2.3 - 3.9 kgf.cm, +1.8 - 3.5 in. lbf) 

       Used bearing: 

       Driven pinion preload +0.15 - 0.30 N.m 

       (+1.6 - 3.1 kgf.cm, +1.3 - 2.7 in. lbf) 

    NOTE: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
66. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST, drive the oil seal into the right bearing retainer to the position shown.

       SST 09223-4601 1

       NOTE: Drive it in carefully so that it will not be tilted.
    2. Apply MP grease to the oil seal lip.
    Fig 84: Installing Transfer Rh Bearing Retainer Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
67. INSTALL TRANSFER CASE OIL SEAL 
    1. Using SST, drive the case oil seal into the case to the position shown.

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

       NOTE: Drive it in carefully so that it will not be tilted.
    2. Apply small amount of MP grease to the oil seal lip.
    Fig 85: Installing Transfer Case Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
68. INSTALL CTR DIFFERENTIAL LOCK SLEEVE 
    1. Apply hypoid gear oil to a new O-ring.
    2. Install the O-ring to the center differential lock sleeve.
       NOTE: Be careful not to twist the O-ring and fit it into the retainer's groove properly.
       Fig 86: Installing CTR Differential Lock Sleeve

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the center differential lock sleeve to the case.

       SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)

       Fig 87: Installing Center Differential Lock Sleeve To Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a snap ring pliers, install the shaft snap ring.
       NOTE: Check that the snap ring is fitted in the groove of the center differential control coupling assy.
    Fig 88: Installing Shaft Snap Ring

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
69. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST, drive the oil seal into the extension housing to the position shown.

       SST 09950-60010 (09951-00380, 09951-00580, 09952-06010), 09950-70010 (09951-07150)

       NOTE: Drive it in carefully so that it will not be tilted.
    2. Apply small amount of MP grease No. 2 to the oil seal lip.
    Fig 89: Installing Transfer Extension Housing Type T Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
70. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR 
    1. Using SST and a press, install the dust deflector to the extension housing.

       SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)

    Fig 90: Installing Transfer Extension Housing Dust Deflector

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
71. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSY 
    1. Apply sealant 1281 to the extension housing in continuous beaded form of 1.2 mm diameter as shown.
       NOTE:

       • Remove any grease from the attaching surfaces.
       • Attach it within 10 minutes. after application of the sealant.
       Fig 91: Applying Sealant To Extension Housing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the extension housing to the case with the 4 bolts.

       Torque: 26 N.m (260 kgf.cm, 19 ft.lbf) 

    3. Remove the transfer assy from the overhaul attachment.
    Fig 92: Removing Transfer Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
72. INSTALL TRANSFER & TRANSAXLE SETTING STUD BOLT 
    1. Install the stud bolts to the parts of the case as shown.

       Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

    NOTE: Install the stud bolt as its sealant-coated side faces the case.
    Fig 93: Installing Transfer & Transaxle Setting Stud Bolt

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
73. INSTALL TRANSFER CASE STRAIGHT PIN 
    1. Using a plastic hammer, drive the straight pins into the transfer assy case as shown.
    Fig 94: Installing Transfer Case Straight Pin

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
74. INSTALL TRANSFER DYNAMIC DAMPER 
    1. Install the dynamic damper to the extension housing with the 3 bolts.

       Torque: 26 N.m (260 kgf.cm, 19 ft.lbf) 

    Fig 95: Installing Transfer Dynamic Damper

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
75. INSTALL BREATHER OIL DEFLECTOR 
    1. Install the breather oil deflector to the case cover with the bolt.

       Torque: 6.5 N.m (66 kgf.cm, 57 in. lbf) 

    NOTE: Be careful about the direction of the deflector's folding.
    Fig 96: Installing Breather Oil Deflector

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
76. INSTALL TRANSFER CASE COVER NO. 1 
    1. Apply sealant 1281 to the case cover in continuous beaded form of 1.2 mm diameter as shown.
       NOTE:

       • Remove any grease from the attaching surfaces.
       • Attach it within 10 minutes. after application of the sealant.
       Fig 97: Applying Sealant To Case Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the case cover to the case with the 8 bolts.

       Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

    Fig 98: Installing Case Cover To Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
77. INSTALL TRANSFER CASE BREATHER PLUG 
    1. Using SST and a hammer, install the breather plug to the case cover.

       SST 09612-10061

    Fig 99: Installing Transfer Case Breather Plug

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
78. INSTALL TRANSFER COVER GASKET 
    1. Install a new gasket to the case.
    Fig 100: Installing Transfer Cover Gasket

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
79. INSTALL TRANSFER ASSY 
    1. Apply sealant 1281 to the transaxle assy and the transfer assy in continuous beaded form of 1.2 mm diameter as shown.
       NOTE:

       • Remove any grease from the attaching surfaces.
       • Install it within 10 minutes. after application of the sealant.
       • Sealant stuck on the gasket, case oil seal and driving plug may cause oil leakage and seizure due to oil shortage. Care must be taken.
       Fig 101: Applying Sealant To Transaxle Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transfer assy to the transaxle assy with the 2 bolts and 6 nuts.

       Torque: 69 N.m (700 kgf.cm, 51 ft.lbf) 

       NOTE:

       • Check that the gasket is installed to the transfer assy before installing them to the transaxle assy.
       • Install the transfer assy to the transaxle assy without tilting.
       • When moving the transfer assy, do not hold the oil seal by both sides.
    Fig 102: Installing Transfer Assy To Transaxle Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
80. AUTOMATIC TRANSMISSION W/TRANSFER (See  REPLACEMENT  ) 
81. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See )  REPLACEMENT 
82. INSTALL TRANSFER DRAIN PLUG 
    1. Install the drain plug with a new gasket.

       Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

    Fig 103: Installing Transfer Drain Plug

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
83. INSTALL TRANSFER CASE NO. 2 PLUG 
    1. Install the No. 2 plug with a new gasket.

       Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

84. INSTALL TRANSFER CASE NO. 1 PLUG 
    1. Supply oil up to the level 0 - 5 mm below the lowest end of the plug hole.

       Oil quantity: 0.9 L (0.95 US qts, 0.71 Imp. qts) 

       NOTE: When supplying oil, fill it slowly.
    2. Install the No. 1 plug with a new gasket.

       Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

85. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See )  ADJUSTMENTS & INSPECTION 
86. CHECK ABS SPEED SENSOR SIGNAL 
    1. ABS WITH EBD & BA & TRAC & VSC SYSTEM (See PRE-CHECK )