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Transfer Assembly: Disassembly

  1. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Remove the 4 bolts and the case cover sub-assembly.
  2. REMOVE BREATHER OIL DEFLECTOR SUB-ASSEMBLY 
    Fig 1: Identifying Case Cover Sub-Assembly With Bolts
    G04963812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY 
    1. Remove the 5 bolts and the front bearing retainer sub-assembly.

      HINT:

      If necessary, tap the retainer sub-assembly with a plastic hammer to remove it.

      Fig 2: Removing Front Bearing Retainer Sub-Assembly And Bolts
      G06082929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL (for R155F/A750F) 
    1. Using a screwdriver and hammer, remove the transfer RH bearing retainer oil seal.
  5. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL (for RA60F) 
    1. Using a screwdriver and hammer, remove the 2 transfer RH bearing retainer oil seals.
  6. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut.
    2. Using SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut.

      SST 09330-00021 

      Fig 3: Holding Output Shaft Companion Flange
      G06082930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the output shaft companion flange sub-assembly (front side).

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

      Fig 4: Removing Output Shaft Companion Flange Lock Nut
      G06082931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using a screwdriver and hammer, remove the companion flange oil seal.
  8. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Remove the rear output shaft companion flange sub-assembly using the same procedure as for the front output shaft companion flange sub-assembly (rear side).

      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 
    1. Using a screwdriver and hammer, remove the companion flange oil seal.
  10. REMOVE SPEEDOMETER DRIVEN GEAR SUB-ASSEMBLY (for R155F/RA60F) 
    1. Remove the bolt and speedometer driven gear w/ sensor.
  11. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (for A750F) 
    1. Remove the bolt and speedometer hole cover sub-assembly.
  12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY FRONT 
    1. Remove the 5 bolts and extension housing sub-assembly.

      HINT:

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

      Fig 5: Removing Extension Housing Sub-Assembly With Bolts
      G06082932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using a screwdriver and hammer, remove the type T oil seal.
  14. REMOVE TRANSFER OUTPUT SHAFT WASHER 
  15. REMOVE TRANSFER SPEEDOMETER DRIVE GEAR 
    1. Remove the speedometer drive gear.
    2. Using a magnetic finger, remove the speedometer drive gear ball.
  16. REMOVE TRANSFER REAR CASE 
    1. Remove the 12 bolts and 2 brackets.
    2. Remove the transfer case rear.

      HINT:

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

      Fig 6: Identifying Transfer Rear Case With Bolts And Brackets
      G06082933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT 
    1. Using a hexagon wrench (6 mm), remove the 2 shift detent ball spring plugs, 2 shift fork compression springs and 2 shift detent balls.
      Fig 7: Installing Shift Detent Balls And Compression Springs Onto Shift Forks
      G06082934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers and a hammer, tap out the 2 shift fork shaft snap rings.
      Fig 8: Tapping Out Shift Fork Shaft Snap Rings
      G06082935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and shift shaft stopper.
      Fig 9: Identifying Shift Shaft Stopper With Bolt
      G06082936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. To pull out the shift fork shaft, shift the shift fork No. 1 and No. 2 to the positions shown in the illustration.
    5. Pull out the shift fork shaft.
      Fig 10: Pulling Out Shift Fork Shaft
      G06082937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a magnetic finger, remove the 2 shift inter lock pins.
      Fig 11: Identifying Shift Inter Lock Pins Onto Shift Forks
      G06082938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE REAR OUTPUT SHAFT ASSEMBLY, FRONT DRIVE CHAIN, DRIVEN SPROCKET ASSEMBLY, SHIFT FORK NO. 1 AND NO. 2 
    1. Using 2 screwdrivers and a hammer, tap out the shift fork shaft snap ring.

      HINT:

      Remove only the snap ring on the front side of the shift fork shaft.

      Fig 12: Tapping Out Shift Fork Shaft Snap Ring
      G06082939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, remove the output shaft snap ring.
      Fig 13: Removing Output Shaft Snap Ring
      G06082940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mount the transfer case rear in a vise.
    4. Using a plastic hammer, carefully tap the transfer case rear and remove the rear output shaft assembly, driven sprocket assembly, front drive chain, shift fork No. 1 and No. 2.
    5. Remove the driven sprocket assembly, front drive chain, shift fork No. 1 and No. 2 from the rear output shaft assembly.
      Fig 14: Installing Rear Output Shaft Assembly, Front Drive Chain, Driven Sprocket Assembly And Shift Forks
      G06082941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY 
    1. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring.
    2. Remove the 3 bolts and shift actuator assembly.
      Fig 15: Removing Bolts And Shift Actuator Assembly
      G06082942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE TRANSFER INDICATOR SWITCH NO.1 
    1. Remove the O-ring, the 2 indicator switches No. 1 and 2 gaskets.
      Fig 16: Installing Gaskets And Indicator Switches
      G06082943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    1. Using SST and a press, remove the driven sprocket bearing.

      SST 09527-10011 

      Fig 17: Removing Driven Sprocket Bearing
      G06082944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING 
    1. Using SST, a press and steel bar, remove the input gear radial ball bearing.

      SST 09555-55010 

  23. REMOVE TRANSFER CASE PLUG 
    1. Remove the transfer case plug No. 1 (filler plug) and gasket.
      Fig 18: Removing Input Gear Radial Ball Bearing
      G04963828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSFER CASE PLUG 
    1. Remove the transfer case plug (drain plug) and gasket.
  25. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Remove the 3 bolts and oil separator sub-assembly.
  26. REMOVE TRANSFER CASE MAGNET 
    Fig 19: Locating Oil Separator Sub-Assembly And Bolts
    G06082946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Remove the 3 bolts and oil pump body sub-assembly.
  28. REMOVE TRANSFER OIL PUMP GEAR 
    Fig 20: Locating Oil Pump Body Sub-Assembly With Bolts
    G06082947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE TRANSFER OIL PUMP BODY O-RING 
    1. Using a screwdriver, remove the oil pump body O-ring.
      Fig 21: Locating Oil Pump Body O-Ring
      G06082948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY 
    1. Using a snap ring expander, remove the low planetary gear bearing shaft snap ring.
      Fig 22: Installing Shaft Snap Ring
      G06082949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the low planetary gear assembly w/ input shaft assembly.
      Fig 23: Removing Low Planetary Gear Assembly W/ Input Shaft Assembly
      G06082950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE TRANSFER CASE PLUG 
    1. Remove the case plug.
    2. Using a magnetic finger, remove the spring and pin.
      Fig 24: Installing Pin And Spring
      G06082951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    1. Using a screwdriver, remove the hole snap ring.
    2. Remove the low planetary ring gear from the front case.
  33. REMOVE TRANSFER CASE OIL SEAL 
    1. Using a screwdriver and hammer, remove the transfer case oil seal.
      Fig 25: Removing Hole Snap Ring
      G06082952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, remove the low planetary gear shaft snap ring.
      Fig 26: Removing Low Planetary Gear Shaft Snap Ring
      G06082953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the low planetary gear spline piece.
      Fig 27: Removing Low Planetary Gear Spline Piece
      G06082954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
    Fig 28: Identifying Transfer Output Shaft Front Needle Roller Bearing
    G06082955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    1. Using a snap ring expander, remove the input gear stopper shaft snap ring.
      Fig 29: Removing Input Gear Stopper Shaft Snap Ring
      G04963893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE TRANSFER INPUT GEAR STOPPER 
  38. REMOVE TRANSFER INPUT GEAR STOPPER BALL 
  39. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER 
    Fig 30: Identifying Manual Transfer Planetary Carrier Washer
    G06082957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE TRANSFER INPUT SHAFT 
  41. REMOVE TRANSFER NO. 1 THRUST BEARING RACE 
  42. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    Fig 31: Removing Transfer Low Planetary Gear Bearing
    G06082958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE TRANSFER NO. 1 INPUT SHAFT SEAL RING 
    1. Remove the 2 seal rings No. 1.
      Fig 32: Identifying Transfer No. 1 Input Shaft Seal Ring
      G06082959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE TRANSFER INPUT SHAFT BEARING 
    1. Using a snap ring expander, remove the input bearing shaft snap ring.
    2. Using SST and a press, remove the input shaft bearing.

      SST 09554-30011, 09555-55010 

      Fig 33: Removing Transfer Input Shaft Bearing
      G06082960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    1. Using SST, remove the low planetary gear bearing.

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

      NOTE: Hang SST securely to the clearance between the bearing and the low planetary gear.
      Fig 34: Removing Low Planetary Gear Bearing
      G04963848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSPECT DRIVE SPROCKET THRUST CLEARANCE 
    1. Using a feeler gauge, measure the drive sprocket thrust clearance.

      Standard clearance: 

      0.10 to 0.25 mm (0.0039 to 0.0098 in.) 

      Maximum clearance: 

      0.25 mm (0.0098 in.) 

      If the clearance exceeds the maximum, replace the drive sprocket.

      Fig 35: Measuring Drive Sprocket Thrust Clearance
      G06082962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE TRANSFER CLUTCH HUB 
    1. Using a snap ring expander, remove the clutch hub shaft snap ring.
    2. Remove the high and low clutch sleeve.
      Fig 36: Removing Clutch Hub Shaft Snap Ring
      G06082963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a press, remove the clutch hub.
      Fig 37: Removing Clutch Hub
      G06082964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST and a press, remove the bearing.

      SST 09555-55010 

      Fig 38: Removing Bearing
      G06082965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
    1. Remove the output shaft spacer and output shaft spacer ball.
    2. Remove the drive sprocket sub-assembly, synchronizer inner ring, center ring, outer ring and drive clutch sleeve together.
      Fig 39: Removing Synchronizer Inner Ring, Center Ring, Outer Ring And Drive Clutch Sleeve
      G06082966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the drive sprocket bearing.
    4. Remove the synchronizer inner ring, center ring, outer ring and drive clutch sleeve.
    5. Remove the 3 synchromesh shifting keys No. 1 and the 2 synchromesh shifting key springs No. 1.
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