Transfer Assembly: Disassembly

REMOVE HEAT INSULATOR BRACKET
1. Remove the heat insulator bracket.
  
  Fig 1: Locating Heat Insulator Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE PLUG
1. Using a 10 mm hexagon wrench, remove the case plug, compression spring, ball and relief valve seat.
  
  Fig 2: Locating Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OIL PUMP PLATE
1. Remove the 4 bolts and oil pump plate.
  NOTE: Do not drop the oil pump drive rotor and oil pump driven rotor.
  
  Fig 3: Locating Oil Pump Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil seal ring from the input shaft.
  
  Fig 4: Identifying Oil Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the drive rotors.
  
  Fig 5: Identifying Drive Rotors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the O-ring from the transfer oil pump plate.
  
  Fig 6: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE STRAIGHT PIN
1. Remove the 2 straight pins.
  NOTE: Do not drop the straight pins.
  
  Fig 7: Identifying Straight Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OIL PUMP PLATE OIL SEAL
1. Using a screwdriver and hammer, tap out the oil seal from the oil pump plate.
  NOTE: Be careful not to damage the oil seal and oil pump plate contact surfaces.
  
  Fig 8: Identifying Transfer Oil Pump Plate Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Using SST and hammer, loosen the staked part of the lock nut.
  SST 09930-00010
  
  Fig 9: Tapping Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the companion flange.
  SST 09330-00021
3. Using a socket wrench (32mm), remove the lock nut.
  
  Fig 10: Holding Companion Flange With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the O-ring.
  
  Fig 11: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the front output shaft companion flange sub-assembly.
  
  Fig 12: Identifying Front Output Shaft Companion Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE FRONT OIL SEAL
1. Using SST, remove the oil seal from the front case.
  NOTE: Be careful not to damage the front case contact surfaces.
  
  Fig 13: Removing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Using SST and hammer, loosen the staked part of the lock nut.
  SST 09930-00010
  
  Fig 14: Tapping Rear Output Shaft Companion Flange Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the companion flange.
  SST 09330-00021
3. Using a socket wrench (32mm), remove the lock nut.
  
  Fig 15: Holding Companion Flange With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the O-ring.
  
  Fig 16: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the rear output shaft companion flange sub-assembly.
  
  Fig 17: Identifying Rear Output Shaft Companion Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE REAR OIL SEAL
1. Using a screwdriver and hammer, tap out the oil seal from the rear case.
  NOTE: Be careful not to damage the rear case contact surfaces. Remove the 2 output washers.
  
  Fig 18: Removing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 19: Identifying Output Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TRANSFER CASE PLUG
1. Remove the No. 1 transfer case plug, compression spring and pin.
  
  Fig 20: Identifying No. 1 Transfer Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE PLUG
1. Using a 6 mm hexagon wrench, remove the case plug.
  
  Fig 21: Locating Transfer Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR TRANSFER CASE
1. Remove the 14 bolts.
2. Remove the rear case.
  HINT:
  
  If necessary, tap the rear case with a plastic-faced hammer to remove it.
  
  Fig 22: Locating Rear Transfer Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
1. Remove the transfer output shaft front needle roller bearing from the output shaft.
  
  Fig 23: Identifying Transfer Output Shaft Front Needle Roller Bearing From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the output shaft spacer from the output shaft.
  
  Fig 24: Identifying Output Shaft Spacer From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 SYNCHRONIZER RING
1. Remove the No. 1 synchronizer ring from center differential case.
  
  Fig 25: Identifying No. 1 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY
1. Using 2 screwdrivers and a hammer, tap out the 3 shift fork shaft snap rings.
  
  Fig 26: Locating Shift Fork Shaft Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts.
  
  Fig 27: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 bolts. Then remove the shift actuator, No.1 gear shift fork and No.2 gear shift fork from the rear case.
  
  Fig 28: Locating Shift Actuator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the o-ring from the transfer shift actuator assembly.
  
  Fig 29: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the washer from the rear case.
  
  Fig 30: Locating Washer From Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER HIGH AND LOW CLUTCH SLEEVE
1. Remove the transfer high and low clutch sleeve from the output shaft.
  
  Fig 31: Identifying Transfer High And Low Clutch Sleeve From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR OUTPUT SHAFT
1. Using a snap ring expander, remove the snap ring.
  
  Fig 32: Identifying Snap Ring With Snap Ring Expander
  Courtesy 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.
3. Remove the output shaft and driven sprocket from the drive chain.
  
  Fig 33: Tapping Case Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a snap ring expander, remove the snap ring from the rear transfer case.
REMOVE SIDE GEAR SHAFT HOLDER BEARING

Fig 34: Identifying Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, remove the snap ring.
  
  Fig 35: Identifying Side Gear Shaft Holder Bearing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the bearing.
  SST 09308-00010
  
  Fig 36: Removing Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY
1. Remove the 3 bolts and oil separator.
  
  Fig 37: Locating Oil Separator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the oil separator.
  
  Fig 38: Identifying O-Ring From Oil Separator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE MAGNET
1. Remove the transfer case magnet.
  
  Fig 39: Identifying Transfer Case Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT ASSEMBLY
1. Using a 14 mm hexagon wrench, remove the 2 case plugs from the front case.
  
  Fig 40: Locating Case Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the snap ring. Then remove the input shaft from the front case.
  
  Fig 41: Locating Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER LOW PLANETARY RING GEAR
1. Remove the low planetary ring gear from the front case.
  
  Fig 42: Identifying Low Planetary Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screw driver, remove the snap ring from the front transfer case.
  
  Fig 43: Identifying Snap Ring From Front Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVEN SPROCKET BEARING
1. Using a screwdriver, remove the snap ring.
  
  Fig 44: Identifying Transfer Driven Sprocket Bearing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the driven sprocket bearing from the front case.
  SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
  
  Fig 45: Tapping Driven Sprocket Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING
1. Remove the oil seal ring from the input shaft.
  
  Fig 46: Identifying No. 1 Transfer Input Shaft Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT SHAFT BEARING
1. Using a snap ring expander, remove the snap ring.
  
  Fig 47: Identifying Transfer Input Shaft Bearing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, pull out the bearing.
  SST 09555-55010, 09950-00030, 09950-60010 (09951-00480)
  
  NOTE: Be careful not to drop or damage the low planetary gear.
  
  Fig 48: Pulling Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH
1. Using SST, remove the bush.
  SST 09387-00041 (09387-01021, 09387-01030, 09387-01040)
  
  Fig 49: Pulling Transfer Input Shaft Bimetal Formed Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT SHAFT PLUG
1. Using SST and a hammer, tap out the input shaft plug.
  SST 09950-70010 (09951-07150), 09950-60010 (09951-00350)
  
  Fig 50: Tapping Input Shaft Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER
1. Using 2 screwdrivers, tap out the snap ring.
  
  Fig 51: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the output shaft spacer from the output shaft.
  
  Fig 52: Identifying Output Shaft Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the seal ring from the output shaft spacer.
  
  Fig 53: Identifying Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER DIFFERENTIAL CASE
1. Remove the straight pin from the output shaft.
2. Remove the center differential case from the output shaft.
  
  Fig 54: Locating Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a snap ring expander, remove the snap ring.
  
  Fig 55: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the synchromesh shifting key spring and No. 2 synchromesh shifting keys from the center differential case.
  
  Fig 56: Identifying Synchromesh Shifting Key Spring And No. 2 Synchromesh Shifting Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE CLUTCH SLEEVE
1. Remove the front driver clutch sleeve with synchromesh from the output shaft.
  
  Fig 57: Locating Front Driver Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 transfer clutch hub bearings from shaft.
  
  Fig 58: Locating Transfer Clutch Hub Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the synchronizer ring set from the drive clutch sleeve.
  
  Fig 59: Identifying Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a screw driver, remove the 2 shifting key snap rings and 3 shifting keys from the driver clutch sleeve.
  
  Fig 60: Locating Shifting Key Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the transfer clutch hub from the drive clutch sleeve.
  
  Fig 61: Identifying Transfer Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR TRANSFER OUTPUT SHAFT
1. Using SST and a press, press out the bearing.
  SST 09527-10011
  
  NOTE: Be careful not to drop or damage the output shaft.
  
  Fig 62: Pressing Bearing With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the transfer drive sprocket sub-assembly from the output shaft.
  
  Fig 63: Identifying Transfer Drive Sprocket Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the needle roller bearing from the output shaft.
  
  Fig 64: Identifying Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002