Transfer Assembly: Disassembly

REMOVE TRANSFER OIL PUMP PLATE
1. Remove the 4 bolts and oil pump plate, oil pump drive rotor and oil pump driven rotor.
  NOTE: Do not drop the oil pump drive rotor and oil pump driven rotor.
  
  Fig 1: Identifying Transfer Oil Pump Plate Bolts
  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 2: Identifying Transfer Case Straight Pins
  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.
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.
REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Using a chisel and hammer, loosen the staked part of the lock nut.
  
  Fig 4: Loosening Staked Part Of Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the companion flange, remove the lock nut.
  SST 09330-00021
  
  Fig 5: Removing Lock Nut Using SST
  Courtesy 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 6: Removing Companion Flange Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE FRONT OIL SEAL
1. Using a screwdriver and hammer, tap out the oil seal from the front case.
  NOTE: Be careful not to damage the front case contact surfaces.
REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Using a chisel and hammer, loosen the staked part of the lock nut.
  
  Fig 7: Loosening Staked Part Of Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the companion flange, remove the lock nut.
  SST 09330-00021
  
  Fig 8: Removing Lock Nut Using SST
  Courtesy 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 9: Removing Companion Flange Using SST
  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 NO. 1 TRANSFER CASE PLUG
1. Remove the case plug, compression spring and pin.
  
  Fig 10: Identifying Case Plug, Compression Spring And Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE PLUG
1. Using a 10 mm hexagon wrench, remove the case plug.
  
  Fig 11: Identifying 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 12: Identifying Rear Transfer Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 TRANSFER GEAR SHIFT FORK
1. Using 2 screwdrivers and a hammer, tap out the 3 shift fork shaft snap rings.
  
  Fig 13: Identifying Shift Fork Shaft Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt. Then remove the No. 2 gear shift fork together with the high and low clutch sleeve from the shift actuator.
  
  Fig 14: Identifying No. 2 Gear Shift Fork Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TRANSFER GEAR SHIFT FORK
1. Remove the bolt. Then remove the No. 1 gear shift fork together with the front drive clutch sleeve from the shift actuator.
  
  Fig 15: Identifying No. 1 Gear Shift Fork Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY
1. Remove the 3 bolts. Then remove the shift actuator from the rear case.
  
  Fig 16: Identifying Shift Actuator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR OUTPUT SHAFT
1. Using a snap ring expander, remove the snap ring.
  
  Fig 17: Removing Snap Ring
  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.
  NOTE: Do not drop the transfer output washer.
REMOVE SIDE GEAR SHAFT HOLDER BEARING
1. Using a screwdriver, remove the snap ring.
  
  Fig 19: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, remove the bearing.
  
  Fig 20: Removing Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY
1. Remove the 3 bolts and oil separator.
Fig 21: Identifying Oil Separator Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE MAGNET
REMOVE INPUT SHAFT ASSEMBLY
1. Using a 10 mm hexagon wrench, remove the 2 case plugs from the front case.
  
  Fig 22: Identifying Case Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, remove the snap ring. Then remove the input shaft from the front case.
  
  Fig 23: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER LOW PLANETARY RING GEAR
1. Using a screwdriver, remove the snap ring. Then remove the low planetary ring gear from the front case.
  
  Fig 24: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVEN SPROCKET BEARING
1. Using a screwdriver, remove the snap ring. Then remove the driven sprocket bearing from the front case.
  
  Fig 25: Removing Transfer Driven Sprocket Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OIL SEAL RING
1. Remove the oil seal ring from the input shaft.
  
  Fig 26: Identifying Transfer Oil Seal Ring
  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 27: 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 28: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press out the bearing.
  SST 09555-55010
  
  NOTE: Be careful not to drop or damage the low planetary gear.
  
  Fig 29: Pressing Out Bearing Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER LOW PLANETARY GEAR ASSEMBLY
1. Using a screwdriver, remove the snap ring.
2. Remove the transfer low planetary gear assembly and transfer low planetary gear spline piece from the transfer input shaft.
  
  Fig 30: Identifying Transfer Low Planetary Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT SHAFT PLUG
1. Using SST and a hammer, tap out the input shaft plug.
  SST 09316-60011 (09316-00011)
  
  Fig 31: Tapping Out 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. Then remove the output shaft spacer and front output shaft needle roller bearing from the output shaft.
  
  Fig 32: Identifying No. 1 Transfer Output Shaft Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER SYNCHROMESH SHIFTING KEY SPRING
1. Using a snap ring expander, remove the snap ring. Then remove the synchromesh shifting key spring and synchromesh shifting key from the output shaft.
  
  Fig 33: Identifying Transfer Synchromesh Shifting Key Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CLUTCH HUB
1. Using a snap ring expander, remove the snap ring.
2. Using SST and a press, press out the clutch hub.
  SST 09527-10011
  
  NOTE: Be careful not to drop or damage the output shaft.
  
  Fig 34: Pressing Out Clutch Hub Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING
1. Using SST and a press, press out the bearing.
  SST 09555-55010
  
  NOTE: Be careful not to drop or damage the output shaft.
2. Remove the drive sprocket and drive sprocket bearing.
3. Remove the synchronizer ring set.
  
  Fig 35: Identifying Rear Transfer Output Shaft Radial Ball Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVE CLUTCH HUB
1. Using 2 screwdrivers, tap out the snap ring.
  
  Fig 36: Tapping Out Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press out the drive clutch hub.
  SST 09527-10011
  
  Fig 37: Pressing Out Drive Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 No. 1 synchromesh shifting key springs from the drive clutch hub.
  
  Fig 38: Identifying No. 1 Synchromesh Shifting Key Springs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002