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Transfer Assembly: Disassembly

  1. REMOVE TRANSFER INDICATOR SWITCH 
    1. Remove the switches and gaskets.

      HINT:

      Indicator switch:

      TRANSFER INDICATOR SWITCH

      No. 1 Indicator switch (neutral position)
      No. 2 Indicator switch (L4 position)
      No. 3 Indicator switch (4WD position)
      Fig 1: Identifying Transfer Indicator Switches
      G05111429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE TRANSFER CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY 
    1. Remove the 4 bolts and the retainer.
      Fig 2: Identifying Transfer Control Shift Lever Retainer Bolts
      G05111430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE BREATHER OIL DEFLECTOR 
  4. REMOVE TRANSFER BEARING RETAINER SUB-ASSEMBLY 
    1. Remove the 5 bolts and the bearing retainer.

      HINT:

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

      Fig 3: Identifying Transfer Bearing Retainer Bolts
      G05111431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSFER COVER 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.
  6. 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 4: Removing Lock Nut
      G04963813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the companion flange.

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

      Fig 5: Removing Companion Flange
      G04963814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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.
  8. 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) 

  9. 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.
  10. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Remove the bolt and speedometer driven hole cover sub-assembly.
  11. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 5 bolts and extension housing.

      HINT:

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

  12. REMOVE TRANSFER COVER 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.
  13. REMOVE TRANSFER OUTPUT WASHER 
  14. REMOVE REAR TRANSFER CASE 
    1. Remove the 12 bolts and clamp.
    2. Remove the rear case.

      HINT:

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

      Fig 6: Identifying Rear Transfer Case Bolts & Clamp
      G05111434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FRONT TRANSFER DRIVE SHIFT FORK SHAFT 
    1. Using a hexagon wrench, remove the 2 plugs.
    2. Using a magnetic finger, remove the 2 springs and 2 balls from both holes.
    3. Mount the case rear in a vise.
      NOTE: Place aluminum plates on the vise to prevent damage to the case rear.
      Fig 7: Identifying Springs & Balls
      G05111435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a pin punch and hammer, tap out the 2 slotted pins from the shift shaft stopper and No. 2 gear shift fork.
      Fig 8: Tapping Out Slotted Pins From Shift Shaft Stopper & No. 2 Gear Shift
      G05111436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Hold the shift fork shaft in place by hand when removing the pin punch.
      Fig 9: Removing Pin Punch Holding Shift Fork Shaft
      G05111437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the shift fork shaft, No. 1 gear shift fork, spring and shift shaft stopper.
      Fig 10: Identifying Shift Fork Shaft, No. 1 Gear Shift Fork, Spring & Shift Shaft Stopper
      G05111438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a magnetic finger, remove the straight pin.
      Fig 11: Identifying Straight Pin
      G05111439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE TRANSFER HIGH AND LOW SHIFT FORK SHAFT 
    1. Remove the shift fork shaft and No. 2 gear shift fork.
      Fig 12: Identifying Shift Fork Shaft & No. 2 Gear Shift Fork
      G05111440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE TRANSFER REAR OUTPUT SHAFT, FRONT TRANSFER DRIVE CHAIN AND TRANSFER DRIVEN SPROCKET 
    1. Using a snap ring expander, remove the snap ring.
      Fig 13: Identifying Snap Ring & Expander
      G05111441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic-faced hammer, carefully tap the case rear, and remove the output shaft together with the drive chain and driven sprocket.
      Fig 14: Removing Output Shaft With Dirve Chain & Driven Sprocket
      G05111442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the output shaft and driven sprocket from the drive chain.
  18. 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 15: Pressing Out Bearing
      G04963827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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 damage the driven sprocket.
      Fig 16: Pressing Out Transfer Input Gear Radial Ball Bearing Using SST, Press & Steel Bar
      G05111444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 1 TRANSFER CASE PLUG (for Filler) 
    1. Remove the filler plug and gasket.
  21. REMOVE NO. 1 TRANSFER CASE PLUG (for Drain) 
    1. Remove the drain plug and gasket.
  22. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Remove the 3 bolts and the oil separator.
      Fig 17: Identifying Oil Separator Sub-Assembly Bolts
      G04963831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE TRANSFER CASE MAGNET 
  24. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Remove the 3 bolts and the oil pump body.
      Fig 18: Identifying Oil Pump Body Bolts
      G05111446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSFER OIL PUMP BODY O-RING 
    1. Using a screwdriver, remove the O-ring from the oil pump body.
      NOTE: Be careful not to damage the oil pump body.
      Fig 19: Identifying Oil Pump Body O-Ring
      G04963833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE TRANSFER OIL PUMP GEAR 
    1. Remove the nut and oil pump gear.
      Fig 20: Identifying Transfer Oil Pump Gear Nut
      G04963834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT 
    1. Using a snap ring expander, remove the snap ring.
      Fig 21: Identifying Snap Ring With Expander
      G04963835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the low planetary gear with input shaft.
      Fig 22: Identifying Low Planetary Gear With Input Shaft
      G05111450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE TRANSFER CASE PLUG 
  29. REMOVE COMPRESSION SPRING 
  30. REMOVE PIN 
    Fig 23: Identifying Compression Spring, Case Plug & Pin
    G05111451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    1. Using a screwdriver, pry out the snap ring.
      NOTE: Be careful not to damage the case front.
    2. Remove the ring gear from the case front.
      Fig 24: Prying Out Snap Ring Using Screwdriver (1 Of 2)
      G04963863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 case front contact surfaces.
  33. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, pry out the snap ring.
      NOTE: Be careful not to damage the low planetary gear.
      Fig 25: Prying Out Snap Ring Using Screwdriver (2 Of 2)
      G05111453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the spline piece.
      Fig 26: Identifying Transfer Low Planetary Gear Spline Piece
      G05111454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
    Fig 27: Identifying Transfer Output Shaft Front Needle Roller Bearing
    G05111455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    1. Using a snap ring expander, remove the snap ring.
      Fig 28: Identifying Transfer Input Gear Stopper Shaft Snap Ring
      G05111456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE TRANSFER INPUT GEAR STOPPER 
  37. REMOVE TRANSFER INPUT GEAR STOPPER BALL 
  38. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER 
    Fig 29: Identifying Manual Transfer Planetary Carrier Washer
    G05111457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE TRANSFER INPUT SHAFT 
    Fig 30: Identifying Transfer Input Shaft
    G05111458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE NO. 1 TRANSFER THRUST BEARING RACE 
  41. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
  42. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    1. Remove the 2 seal rings.
      Fig 31: Identifying Seal Rings
      G05111459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. 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 32: Pressing Out Bearing Using SST & Press
      G05111460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    • Using SST, remove the bearing.

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

      NOTE: Hang SST securely between the bearing and low planetary gear.
      Fig 33: Identifying Transfer Low Planetary Gear Bearing
      G05111461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE TRANSFER CLUTCH HUB 
    1. Using a snap ring expander, remove the snap ring.
    2. Remove the high and low clutch sleeves.
    3. Using a press, press out the clutch hub.
      NOTE: Be careful not to drop or damage the clutch hub.
  46. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY (for A.D.D. Manual Shift Type) 
    1. Using SST and a press, press out the bearing.

      SST 09555-55010 

      NOTE: Be careful not to drop or damage the output shaft.
      Fig 34: Pressing Out Bearing Using SST & Press
      G05111462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the spacer and ball.
    3. Remove the drive sprocket with front drive clutch sleeve.
    4. Remove the needle roller bearing.
    5. Remove the front drive synchronizer ring.
    6. Remove the front drive sleeve, 3 shifting keys and 2 shifting key springs from the drive sprocket.
      Fig 35: Identifying Transfer Drive Sprocket Sub-Assembly (For A.D.D. Manual Shift Type)
      G05111463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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