Transfer Assembly: Reassembly

HINT:

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

INSTALL REAR TRANSFER OUTPUT SHAFT
1. Install a new needle roller bearing.
  
  Fig 1: Identifying Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transfer drive sprocket sub-assembly.
  
  Fig 2: Identifying Transfer Drive Sprocket Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and press, press in a new bearing.
  SST 09308-14010, 09316-20011
  
  NOTE: Make sure the bearing is installed in the correct direction.
  
  Fig 3: Pressing Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE CLUTCH SLEEVE
1. Install the transfer clutch hub onto the front drive clutch sleeve.
  
  Fig 4: Identifying Transfer Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 3 shifting keys and 2 shifting key snap rings
  NOTE: Install the key springs so that their end gaps are not in line.
  
  Fig 5: Identifying Shifting Keys And Shifting Key Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the synchronizer ring set.
  NOTE: Align the slots of the synchronizer outer with the inner rings.
  
  Fig 6: Identifying Synchronizer Ring Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 transfer clutch hub bearings.
  
  Fig 7: Locating Transfer Clutch Hub Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the front drive clutch sleeve with synchromesh onto the output shaft.
  NOTE: Align the cutouts in the front drive sprocket with the protrusions on the center synchronizer ring.
  
  Fig 8: Identifying Front Drive Clutch Sleeve With Synchromesh Onto Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER DIFFERENTIAL CASE
1. Install the synchromesh shifting key spring and No. 2 synchromesh shifting keys as shown in the illustration.
  
  Fig 9: Identifying Synchromesh Shifting Key Spring And No. 2 Synchromesh Shifting Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, install the snap ring.
  
  Fig 10: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the center differential case to the output shaft.
4. Install the straight pin to the output shaft.
  
  Fig 11: Locating Straight Pin To Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER
1. Install a new seal ring to the output shaft spacer.
  
  Fig 12: Identifying Seal Ring To Output Shaft Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the pin with the straight pin groove of the output shaft spacer, and slide on the output shaft spacer.
  
  Fig 13: Aligning Pin With Straight Pin Groove Of Output Shaft Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver and hammer, tap on the snap ring.
  
  Fig 14: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER INPUT SHAFT PLUG
1. Using SST and a hammer, tap in a new input shaft plug until its surface is 1.0 to 1.8 mm (0.0394 to 0.0709 in.) from the input shaft upper surface.
  SST 09950-70010 (09951-07150), 09950-60010 (09951-00380)
  
  NOTE: Be careful not to damage or deform the input shaft plug when tapping it.
  
  Fig 15: Tapping Input Shaft Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER INPUT SHAFT BIMETAL FORMED BUSH
1. Using SST and a hammer, tap in a new bush until its surface is 5.5 to 5.9 mm (0.217 to 0.232 in.) from the input shaft upper surface.
  SST 09950-70010 (09951-07150), 09950-60010 (09951-00610)
  
  NOTE: Be careful not to damage the input shaft.
  
  Fig 16: Identifying Transfer Input Shaft Bimetal Formed Bush Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSFER INPUT SHAFT BEARING

Install the low planetary gear bearing and low planetary gear to the input shaft.
NOTE:
- Make sure that the low planetary gear bearing is installed in the correct direction.
- Install the low planetary gear bearing so that its temper color side faces the low planetary gear.
  
  Fig 17: Identifying Low Planetary Gear Bearing And Low Planetary Gear To Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the low planetary gear bearing and a new input shaft bearing to the input shaft.
NOTE:
- Make sure that the input shaft bearing is installed in the correct direction.
- Make sure that the low planetary gear bearing is installed in the correct direction.
- Install the low planetary gear bearing so that its temper color side faces the low planetary gear.
  
  Fig 18: Identifying Low Planetary Gear Bearing And New Input Shaft Bearing To Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST and a press, press in a new bearing.
SST 09513-36040,09527-17011

NOTE: After press-fitting the bearing to the input shaft, check that the bearing moves smoothly.

Fig 19: Pressing Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring that allows for minimum axial play and install it to the shaft.

Snap Ring Thickness

SNAP RING THICKNESS SPECIFICATION

Mark	Thickness
C	2.13 to 2.18 mm (0.0839 to 0.0858 in.)
D	2.18 to 2.23 mm (0.0858 to 0.0878 in.)
E	2.23 to 2.28 mm (0.0878 to 0.0898 in.)
F	2.28 to 2.33 mm (0.0898 to 0.0917 in.)
G	2.33 to 2.38 mm (0.0918 to 0.0937 in.)
H	2.38 to 2.43 mm (0.0937 to 0.0957 in.)
J	2.43 to 2.48 mm (0.0957 to 0.0976 in.)

Fig 20: Identifying Snap Ring

Using a snap ring expander, install the snap ring.
NOTE: Make sure that the snap ring is firmly installed to the groove.

INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING
1. Apply transfer oil to a new seal ring.
2. Install a new seal ring to the input shaft.
  
  Fig 21: Identifying No. 1 Transfer Input Shaft Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DRIVEN SPROCKET BEARING
1. Install a new bearing to the front case in the direction shown in the illustration.
  SST 09950-60020 (09951-00790), 09950-70010 (09951-07150)
  
  NOTE: Make sure that the bearing is installed in the correct direction.
  
  Fig 22: Tapping Transfer Driven Sprocket Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring.
  
  Fig 23: Identifying Transfer Driven Sprocket Bearing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER LOW PLANETARY RING GEAR
1. Install the snap ring to the front case.
  
  Fig 24: Identifying Snap Ring From Front Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the ring gear to the transfer front case.
  NOTE: Make sure to install the ring gear in the correct direction.
  
  Fig 25: Identifying Ring Gear Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver install the snap ring.
  NOTE: Make sure that the snap ring is firmly installed to the groove.
  
  Fig 26: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT ASSEMBLY
1. While expanding the snap ring, install the input shaft to the front case.
2. Apply adhesive to the threads of the 2 plugs.
  Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  NOTE: Install the plugs within 3 minutes of application.
  
  Fig 27: Locating Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a 14 mm hexagon wrench, install the 2 plugs.
  Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
  
  Fig 28: Locating Case Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE MAGNET
1. Install the transfer case magnet.
  
  Fig 29: Identifying Transfer Case Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY
1. Install a new O-ring.
  
  Fig 30: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil separator with the 3 bolts.
  Torque: 18 N*m (178 kgf*cm, 13 ft.*lbf)
  
  Fig 31: Locating Oil Separator With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SIDE GEAR SHAFT HOLDER BEARING
1. Using SST and hammer, install a new side gear shaft holder bearing.
  SST 09950-60010 (09951-00590), 09950-70010 (09951-07150)
  
  Fig 32: Tapping Side Gear Shaft Holder Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring.
INSTALL REAR OUTPUT SHAFT
1. Install the snap ring to the rear case.
2. Mount the rear case in a vise.
  NOTE: Place aluminum plates on the vise to prevent damage to the rear case.
  
  Fig 33: Identifying Side Gear Shaft Holder Bearing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rear output shaft, front drive chain and driven sprocket.
  NOTE: Do not drop the clutch sleeve or shifting key.
  
  Fig 34: Identifying Rear Output Shaft, Front Drive Chain And Driven Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a snap ring expander, install the snap ring to the out put shaft.
  NOTE: Make sure that the snap ring is firmly installed to the groove.
  
  Fig 35: Identifying Snap Ring With Snap Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER HIGH AND LOW CLUTCH SLEEVE
1. Install the transfer high and low clutch sleeve to the output shaft.
  
  Fig 36: Identifying Transfer High And Low Clutch Sleeve From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY
1. Install the washer to the rear case.
  
  Fig 37: Locating Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new O-ring to the shift actuator.
  
  Fig 38: Locating O-Ring To Shift Actuator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set the No. 1 gear shift fork and No. 2 gear shift fork to the rear case. Then install the shift actuator to the rear case with the 3 bolts.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Fig 39: Locating Shift Actuator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 bolts.
  Torque: 24 N*m (245 kgf*cm, 18 ft.lbf)
  
  Fig 40: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a screwdriver and hammer, tap the 3 shift fork shaft snap rings into the shift fork shaft.
  
  Fig 41: Locating Shift Fork Shaft Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 SYNCHRONIZER RING
1. Align the protrusion of the synchronizer ring with the notch on the differential case and install it.
  
  Fig 42: Identifying No. 1 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
1. Install the output shaft spacer.
  
  Fig 43: Identifying Output Shaft Spacer From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transfer output shaft front needle roller bearing.
  
  Fig 44: Identifying Transfer Output Shaft Front Needle Roller Bearing From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR TRANSFER CASE
1. Apply seal packing to the rear case as shown in the illustration.
  Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
  
  NOTE: If the removed rear case will be reused: After removing the rear case, perform the following before reinstalling it: 1) using a knife, cut off any old FIPG on the rear case's contact surface, 2) clean off any remaining old FIPG from the rear case's contact surface, and 3) reapply seal packing to the rear case.
  
  Fig 45: Identifying Seal Packing Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rear case with the 14 bolts.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  NOTE: Tighten the bolts of the rear case within 10 minutes of applying the seal packing. The seal packing will dry very quickly.
  
  Fig 46: Locating Rear Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE PLUG
1. Apply adhesive to the threads of the plug.
  Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  NOTE: Install the plug within 3 minutes of application.
2. Using a 6 mm hexagon wrench, install the plug.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  Fig 47: Locating Transfer Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSFER CASE PLUG
1. Install the pin and compression spring to the front case.
2. Apply adhesive to the threads of the plug.
  Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  NOTE: Install the plug within 3 minutes of application.
3. Install the plug.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  
  Fig 48: Identifying No. 1 Transfer Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE FRONT OIL SEAL
1. Apply transfer oil to the spline area of the output shaft.
2. Using SST and a hammer, tap in the oil seal until its surface is 1 to 1.5 mm (0.0394 to 0.0591 in.) from the case upper surface.
  SST 09316-60011 (09316-00011)
INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Install the companion flange sub-assembly onto the drive sprocket sub-assembly.
  
  Fig 49: Identifying Transfer Case Front Oil Seal Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the companion flange.
  SST 09330-00021
3. Using a socket wrench (32mm), install a new O-ring and a new companion flange lock nut.
  Torque: 127 N*m (1299 kgf*cm, 94 ft.*lbf)
  
  Fig 50: Holding Companion Flange With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a chisel and hammer, stake the companion flange lock nut.
  
  Fig 51: Identifying Companion Flange Lock Nut Correct And Incorrect Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE REAR OIL SEAL
1. Install the 2 output washers.
2. Apply transfer oil to the spline area of the output shaft.
  
  Fig 52: Identifying Output Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a hammer, tap in a new oil seal until its surface is flush with the housing upper surface.
  SST 09316-60011 (09316-00011)
INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Install the companion flange onto the output shaft.
  
  Fig 53: Identifying Transfer Case Rear Oil Seal Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the companion flange.
  SST 09330-00021
3. Using a socket wrench (32mm), install a new O-ring and a new companion flange lock nut.
  Torque: 127 N*m (1299 kgf*cm, 94 ft.*lbf)
  
  Fig 54: Holding Companion Flange With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a chisel and hammer, stake the companion flange lock nut.
INSTALL TRANSFER OIL PUMP PLATE OIL SEAL SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)

Fig 55: Identifying Companion Flange Lock Nut Correct And Incorrect Position
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump plate upper surface.
  SST 09950-70010 (09951-07100)
  
  NOTE: Be careful not to damage the oil pump plate.
  
  Fig 56: Tapping Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE STRAIGHT PIN
1. Install the 2 straight pins to the input shaft.
INSTALL TRANSFER OIL PUMP PLATE
1. Apply transfer oil to a new O-ring, drive rotor and driven rotor.
  
  Fig 57: Identifying Straight Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the O-ring.
  
  Fig 58: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the drive rotors.
  
  Fig 59: Identifying Drive Rotors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install a new seal ring to the input shaft.
  
  Fig 60: Identifying Seal Ring To Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the oil pump plate with the 4 bolts.
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
  
  Fig 61: Locating Oil Pump Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE PLUG
1. Install the relief valve seat, ball and compression spring to the oil pump plate.
2. Apply adhesive to the threads of the plug.
  Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
3. Using a 10 mm hexagon wrench, install the plug.
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 62: Locating Transfer Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEAT INSULATOR BRACKET
1. Install the heat insulator bracket with the bolt.
  NOTE: Position the bracket against the transfer case rib so that it will not rotate.
  
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Fig 63: Locating Heat Insulator Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002