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Transfer Assembly: Reassembly

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

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

  1. INSTALL PLANETARY RING GEAR 
    1. Install the planetary ring gear.
      NOTE: Make sure that the planetary ring gear is installed in the correct direction. 
      Fig 1: Installing Planetary Ring Gear
      G02638516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the pin and spring.
    3. Apply sealant to the head screw plug threads.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    4. Install the head screw plug.

      Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 

      Fig 2: Installing Head Screw Plug
      G02638517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a screwdriver, install the snap ring.
    NOTE: Make sure the end gap of the snap ring is not aligned with the upper side of the case. 
    Fig 3: Installing Snap Ring Using Screwdriver
    G02638518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL INPUT SHAFT ASSEMBLY, THRUST BEARING AND RACE 
    Fig 4: Installing Input Shaft Assembly, Thrust Bearing And Race
    G02638519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL THRUST WASHER AND INPUT GEAR STOPPER 
    1. Install the thrust washer, ball and input gear stopper.

      HINT:

      Apply gear oil to the input gear stopper and thrust washer.

      Fig 5: Installing Thrust Washer And Input Gear Stopper
      G02638520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select a snap ring that allows for 0.05 to 0.15 mm (0.0020 to 0.0059 in.) axial play.
      SNAP RING REFERENCE

      Mark Thickness mm (in.)
      A 2.10 to 2.15 (0.0827 to 0.0846)
      B 2.15 to 2.20 (0.0846 to 0.0866)
      C 2.20 to 2.25 (0.0866 to 0.0886)
      D 2.25 to 2.30 (0.0886 to 0.0906)
      E 2.30 to 2.35 (0.0906 to 0.0925)
      F 2.35 to 2.40 (0.0925 to 0.0945)
      G 2.40 to 2.45 (0.0945 to 0.0965)
      H 2.45 to 2.50 (0.0965 to 0.0984)
      J 2.50 to 2.55 (0.0984 to 0.1004)
      K 2.55 to 2.60 (0.1004 to 0.1024)
      L 2.60 to 2.65 (0.1024 to 0.1043)
      M 2.65 to 2.70 (0.1043 to 0.1063)
      N 2.70 to 2.75 (0.1063 to 0.1083)
      P 2.75 to 2.80 (0.1083 to 0.1102)
      Q 2.80 to 2.85 (0.1102 to 0.1122)
      R 2.85 to 2.90 (0.1122 to 0.1142)
      S 2.90 to 2.95 (0.1142 to 0.1161)
      T 2.95 to 3.00 (0.1161 to 0.1181)
      U 3.00 to 3.05 (0.1181 to 0.1201)
      Fig 6: Checking Snap Ring
      G02638521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a snap ring expander, install a snap ring.
    Fig 7: Installing Snap Ring Using Snap Ring Expander
    G02638522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NEEDLE ROLLER BEARING TO INPUT SHAFT ASSEMBLY 

    HINT:

    Apply gear oil to the needle roller bearing.

    Fig 8: Installing Needle Roller Bearing To Input Shaft Assembly
    G02638523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL LOW GEAR SPLINE PIECE 
    1. Install the low gear spline piece.
      Fig 9: Installing Low Gear Spline Piece
      G02638524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring.
    NOTE: Make sure the end gap of the snap ring is not aligned with the cutout portion of the planetary carrier. 
    Fig 10: Installing Snap Ring
    G02638525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY 
    1. Install the planetary gear assembly with the input shaft assembly.

      HINT:

      If necessary, heat the front case to about 50 to 80°C (122 to 176°F).

      Fig 11: Installing Planetary Gear Assembly With Input Shaft Assembly
      G02638526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install the snap ring.

    HINT:

    Check that the planetary gear and input shaft assembly turn slightly.

  7. INSTALL OIL PUMP DRIVE GEAR 
    Fig 12: Installing Snap Ring Using Snap Ring Expander
    G02638527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL OIL PUMP BODY ASSEMBLY 

    Install the oil pump body assembly with the 3 bolts.

    Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

    Fig 13: Installing Oil Pump Body Assembly
    G02638528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL MAGNET AND SEPARATOR WITH OIL STRAINER 
    1. Install the magnet to the front case.
    2. Install the separator with oil strainer with the 3 bolts.

      Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf) 

    Fig 14: Installing Separator With Oil Strainer
    G02638529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL ACTUATOR ASSEMBLY 
    1. Install a new O-ring, 2 new gaskets, transfer 4WD position switch and transfer L4 position switch to the actuator assembly.

      Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) 

      HINT:

      Coat a new O-ring with gear oil.

      Fig 15: Installing New O-Ring, New Gaskets, Transfer 4WD Position Switch And Transfer L4 Position Switch
      G02638530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the actuator assembly with the 3 bolts.

      Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

    3. Using a screwdriver and hammer, drive in the snap ring to the shift fork shaft of the actuator assembly.

    HINT:

    Install only the snap ring on the rear side of the shift fork shaft.

    Fig 16: Driving In Snap Ring To Shift Fork Shaft Of Actuator Assembly
    G02638531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR OUTPUT SHAFT ASSEMBLY, DRIVEN SPROCKET ASSEMBLY, CHAIN AND FRONT DRIVE AND HIGH AND LOW SHIFT FORKS 
    1. Install the driven sprocket assembly, chain and front drive and high and low shift forks to the rear output shaft assembly.
      NOTE: Make sure that the front drive and high and low shift forks are installed in the correct direction. 
      Fig 17: Identifying Shift Forks
      G02638532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Mount the rear case in a vise.
    3. Install the rear output shaft assembly, driven sprocket assembly, chain and front drive and high and low shift forks to the rear case as an assembly.
      NOTE: Do not drop the clutch sleeve or shifting key. 

      HINT:

      If necessary, heat the rear case to about 50 to 80 °C (122 to 176°F).

      Fig 18: Installing Rear Output Shaft Assembly
      G02638533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a snap ring expander, install the snap ring.
      Fig 19: Installing Snap Ring Using Snap Ring Expander
      G02638534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a screwdriver and hammer, drive in the snap ring to the shift fork shaft of the actuator assembly.

    HINT:

    Check that the rear output shaft assembly and driven sprocket assembly turn slightly.

    Fig 20: Driving In Snap Ring To Shift Fork Shaft Of Actuator Assembly
    G02638535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL SHIFT FORK SHAFT 
    1. Using a magnetic finger, install the 2 straight pins to the front drive and high and low shift forks.
      Fig 21: Installing 2 Straight Pins
      G02638536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. To push into the shift fork shaft, shift the front drive and high and low shift forks to the positions as shown in the illustration.
    3. Push into the shift fork shaft.
      NOTE: Make sure that the shift fork shaft is installed in the correct direction. 
      Fig 22: Identifying High And Low Shift Forks Positions
      G02638537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the shift fork shaft stopper with the bolt.

      Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 

      Fig 23: Installing Shift Fork Shaft Stopper
      G02638538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a screwdriver and hammer, drive in the 2 snap rings to the shift fork shaft.
      Fig 24: Driving In Snap Rings To Shift Fork Shaft
      G02638539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 2 balls and springs to the front drive and high and low shift forks.
    7. Apply sealant to the straight screw plug threads.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    8. Using a hexagon wrench (6 mm), install the 2 straight screw plugs to the front drive and high and low shift forks.

      Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 

    Fig 25: Installing 2 Straight Screw Plugs To High And Low Shift Forks
    G02638540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REASSEMBLE FRONT AND REAR CASE 

    HINT:

    Remove any FIPG material and be careful not to drop oil on the contacting surface of the rear case.

    1. Apply FIPG to the rear case as shown in the illustration.

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 26: Applying FIPG To Rear Case
      G02638541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 clamps and reassemble the front and rear case with the 12 bolts.
      Fig 27: Installing 2 Clamps
      G02638542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 

  14. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR 
    1. Install the ball to the rear output shaft.
    2. Install the vehicle speed sensor drive gear and 2 output washers.
  15. INSTALL EXTENSION HOUSING 

    HINT:

    Remove any FIPG material and be careful not to drop oil on the contacting surface of the extension housing.

    1. Apply FIPG to the extension housing as shown in the illustration.

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 28: Applying FIPG To Extension Housing
      G02638543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply sealant to the bolt threads.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    3. Install the extension housing with the 5 bolts.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

    Fig 29: Installing Extension Housing
    G02638544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT COMPANION FLANGE 
    1. Install the front companion flange to the input shaft.
    2. Using SST, hold the front companion flange, and install a new front companion flange lock nut.

      SST 09330-00021

      Torque: 118 N.m (1,203 kgf.cm, 87 ft.lbf) 

      Fig 30: Installing New Front Companion Flange Lock Nut Using SST
      G02638545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Stake the front companion flange lock nut.
  17. INSTALL REAR COMPANION FLANGE 

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

  18. INSTALL OIL DEFLECTOR AND UPPER COVER 

    Install 2 new gaskets, oil deflector and upper cover with the 4 bolts.

    Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

  19. INSTALL FRONT BEARING RETAINER 

    HINT:

    Remove any FIPG material and be careful not to drop oil on the contacting surface of the front bearing retainer.

    1. Apply FIPG to the front bearing retainer as shown in the illustration.

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 or equivalent 

    2. Apply sealant to the bolt threads.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Fig 31: Applying FIPG To Front Bearing Retainer
      G02638546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the front bearing retainer with the 5 bolts.

      Torque: 11.5 N.m (117 kgf.cm, 8 ft.lbf) 

      Fig 32: Installing Front Bearing Retainer
      G02638547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL PROTECTOR 

    Install the protector with the 4 bolts.

    Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

    Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

  21. INSTALL SPEEDOMETER DRIVEN GEAR HOLE COVER 
    1. Install a new O-ring to the speedometer driven gear hole cover.

      HINT:

      Coat a new O-ring with gear oil.

    2. Install the speedometer driven gear hole cover with the bolt.

      Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) 

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