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Transfer Assembly: Disassembly

  1. REMOVE TRANSFER INDICATOR SWITCH 
    1. Remove the indicator switches and gaskets.
      Fig 1: Identifying Transfer Indicator Switches
      G05111544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Indicator switch:

      SWITCH REFERENCE TABLE

      No. 2 Indicator switch (L4 position)
      No. 3 Indicator switch (differential lock)
  2. REMOVE TRANSFER GEAR SHIFT HEAD 
    1. Using a pin punch and hammer, tap out the 2 slotted pins from the No. 1 and No. 2 gear shift heads.
    2. Remove the No. 1 and No. 2 gear shift heads from the front drive shift fork shaft and the high and low shift fork shaft.
      Fig 2: Identifying No. 1 & No. 2 Gear Shift Heads
      G05111545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE TRANSFER BEARING RETAINER SUB-ASSEMBLY 
    1. Remove the 5 bolts and the bearing retainer.
      Fig 3: Identifying Transfer Bearing Retainer Bolts
      G05111431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      If necessary, tap the bearing retainer with a plastic-faced hammer to remove it.

  4. REMOVE TRANSFER COVER TYPE T OIL SEAL 
    1. Using a screwdriver and hammer, tap out the oil seal from the bearing retainer.
      NOTE: Be careful not to damage the oil seal and bearing retainer contact surfaces.
  5. REMOVE TRANSFER CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY 
    1. Remove the 4 bolts and retainer.
      Fig 4: Identifying Transfer Control Shift Lever Retainer Bolts
      G05111547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE BREATHER OIL DEFLECTOR 
  7. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Front) 
    1. Using a chisel and hammer, loosen the staked part of the lock nut.
    2. Using SST to hold the companion flange, remove the lock nut.

      SST 09330-00021 

      Fig 5: Removing Lock Nut
      G04963813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the companion flange.
      Fig 6: Removing Companion Flange
      G04963814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) 

  8. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (for Front) 
    1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.
      NOTE: Be careful not to damage the oil seal and companion flange contact surfaces.
  9. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Rear) 
    1. Remove the companion flange (rear) in the same way as the companion flange (front).

      SST 09330-00021,09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) 

  10. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (for Rear) 
    1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.
      NOTE: Be careful not to damage the oil seal and companion flange contact surfaces.
  11. REMOVE SPEEDOMETER DRIVEN GEAR ASSEMBLY WITH VEHICLE SPEED SENSOR  (See REMOVAL  )
  12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 5 bolts and the extension housing.

      HINT:

      If necessary, tap the extension housing with a plastic-faced hammer to remove it.

  13. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using a screwdriver and hammer, tap out the oil seal.
      NOTE: Be careful not to damage the oil seal and extension housing contact surfaces.
  14. REMOVE TRANSFER OUTPUT WASHER 
    1. Remove the 2 washers and the drive gear.
  15. REMOVE REAR TRANSFER CASE 
    1. Remove the 12 bolts and 2 clamps.
    2. Remove the rear case.

      HINT:

      If necessary, tap the rear case with a plastic-faced hammer to remove it.

      Fig 7: Identifying Rear Transfer Case Bolts & Clamps
      G05111550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE 
    1. Mount the rear case in a vise.
      NOTE: Place aluminum plates on the vise to prevent damage to the rear case.
    2. Using a pin punch and hammer, drive out the slotted spring pin.
    3. Using a hexagon wrench, remove the No. 1 plug.
    4. Using a magnetic finger, remove the spring and ball from the hole.
      Fig 8: Driving Out Slotted Spring Pin Using Pin Punch & Hammer
      G05111551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the No. 2 gear shift fork and high and low shift fork shaft.
    6. Using a magnetic finger, remove the straight pin.
    7. Automatic transmission:

      Remove the high and low clutch sleeve.

    8. Manual transmission:

      Remove the high and low clutch sleeve, 3 shifting keys and 2 No. 1 springs.

  17. REMOVE CENTER DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE 
    1. Mount the rear case in a vise.
      NOTE: Place aluminum plates on the vise to prevent damage to the rear case.
    2. Using a pin punch and hammer, drive out the slotted spring pin.
    3. Using 2 screwdrivers and a hammer, tap out the snap ring.
      Fig 9: Driving Out Slotted Spring Pin Using Pin Punch & Hammer
      G05111552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a hexagon wrench, remove the No. 2 plug.
    5. Using a magnetic finger, remove the spring and ball from the hole.
    6. Remove the center differential lock fork, shift shaft stopper, 2 springs. 3 stoppers, front drive shift shaft and front drive clutch sleeve.
  18. REMOVE REAR TRANSFER OUTPUT SHAFT, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY 
    1. Mount the rear case in a vise.
      NOTE: Place aluminum plates on the vise to prevent damage to the rear case.
    2. Using a snap ring expander, remove the snap ring.
      Fig 10: Identifying Snap Ring
      G05111441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic-faced hammer, carefully tap the rear case, and remove the output shaft together with the front drive chain and driven sprocket.
    4. Remove the output shaft and driven sprocket from the front drive chain.
      Fig 11: Identifying Output Shaft & Driven Sprocket
      G05111554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    1. Using a press, press out the bearing.
      NOTE: Be careful not to drop or damage the driven sprocket.
      Fig 12: Pressing Out Bearing
      G04963827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING 
    1. Using SST, a press and steel bar, press out the bearing.

      SST 09555-55010 

      NOTE: Be careful not to drop or damage the driven sprocket.
      2. Fig 13: Pressing Out Transfer Input Gear Radial Ball Bearing Using SST, Press & Steel Bar
      G05111444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 1 TRANSFER CASE PLUG (for Filler) 
    1. Remove the filler plug and gasket.
  22. REMOVE NO. 1 TRANSFER CASE PLUG (for Drain) 
    1. Remove the drain plug and gasket.
  23. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Remove the 3 bolts and separator.
      Fig 14: Identifying Oil Separator Sub-Assembly Bolts
      G04963831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSFER CASE MAGNET 
  25. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Remove the 3 bolts and pump body.
      Fig 15: Identifying Oil Pump Body Sub-Assembly Bolts
      G04963832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE TRANSFER OIL PUMP BODY O-RING 
    1. Using a screwdriver, remove the O-ring from the pump body.
      NOTE: Be careful not to damage the pump body.
      Fig 16: Removing Oil Pump Body O-Ring
      G04963833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE TRANSFER OIL PUMP GEAR 
    1. Remove the nut and pump gear.
      Fig 17: Identifying Transfer Oil Pump Gear
      G04963834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT 
    1. Using a snap ring expander, remove the snap ring.
      Fig 18: Identifying Snap Ring & Expander
      G04963835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the low planetary gear with input shaft.
      Fig 19: Identifying Low Planetary Gear With Input Shaft
      G05111562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE TRANSFER FRONT DRIVE CLUTCH SYNCHRONIZER RING 
  30. REMOVE OUTPUT SHAFT SPACER 
    Fig 20: Identifying Output Shaft Spacer And Output Shaft Needle Roller Bearing
    G05111563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
  32. REMOVE TRANSFER CASE OIL SEAL 
    1. Using a screwdriver and hammer, tap out oil seal No. 1.
    2. Using a screwdriver and hammer, tap out oil seal No. 2.
      NOTE: Be careful not to damage the oil seal and front case contact surfaces.
  33. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    1. Using a snap ring expander, pry out the snap ring.
      Fig 21: Prying Out Snap Ring Using Snap Ring Expander
      G05111564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TRANSFER INPUT GEAR STOPPER 
    35. Fig 22: Identifying Manual Transfer Planetary Carrier Washer & Transfer Input Gear Stopper Ball
    G05111565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE TRANSFER INPUT GEAR STOPPER BALL 
  36. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER 
  37. REMOVE TRANSFER INPUT SHAFT 
    38. Fig 23: Installing Input Shaft Onto Low Planetary Gear
    G05111566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE NO. 1 TRANSFER THRUST BEARING RACE 
  39. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
  40. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    1. Remove the 2 seal rings.
      Fig 24: Identifying Seal Rings
      G05111567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE TRANSFER INPUT SHAFT BEARING 
    1. Using a snap ring expander, remove the snap ring.
    2. Using SST and a press, press out the bearing.

      SST 09554-30011,09555-55010 

      NOTE: Be careful not to drop or damage the low planetary gear.
      Fig 25: Pressing Out Transfer Input Shaft Bearing Using SST & Press
      G05111568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, remove the snap ring.
      NOTE: Be careful not to damage the spline piece.
    2. Remove the spline piece.
      Fig 26: Using Screwdriver To Remove Snap Ring
      G05111569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    1. Using SST, remove the bearing.

      SST 09612-65014 (09612-01030, 09612-01050) 

      NOTE: Hang SST securely between the bearing and low planetary gear.
      Fig 27: Identifying Transfer Low Planetary Gear Bearing
      G05111461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING 
    1. Using a snap ring expander, remove the snap ring.
      Fig 28: Identifying Low Planetary Ring Gear Hole Snap Ring
      G05111571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE NO. 2 TRANSFER OUTPUT SHAFT SPACER 
  46. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL 
  47. REMOVE CENTER DIFFERENTIAL CASE 
  48. REMOVE TRANSFER CLUTCH HUB 
    49. Fig 29: Identifying Transfer Output Shaft Plate Washer
    G05111572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
  50. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER 
  51. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST and a press, press out the bearing.

      SST 09555-55010 

      Fig 30: Pressing Out Bearing Using SST & Press
      G05111573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER 
    53. Fig 31: Identifying Transfer Output Shaft Plate Washer
    G05111574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
  54. REMOVE TRANSFER DRIVE SPROCKET BEARING 
  55. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER 
  56. REMOVE TRANSFER CASE PLUG 
    57. Fig 32: Identifying Compression Spring, Case Plug & Pin
    G05111451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE COMPRESSION SPRING 
  58. REMOVE TRANSFER CASE STRAIGHT PIN 
  59. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    1. Using a screwdriver, pry out the snap ring.
      NOTE: Be careful not to damage the ring gear and front case.
    2. Remove the ring gear from the front case.
      Fig 33: Identifying Snap Ring & Screwdriver
      G04963863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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