Transfer Assembly: Disassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT
1. Remove the stud bolt.
  
  Fig 1: Identifying Transfer And Transaxle Setting Stud Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE STRAIGHT PIN
1. Remove the 2 straight pins.
REMOVE TRANSFER CASE NO. 1 PLUG
1. Remove the No. 1 plug.
2. Remove the gasket from the No. 1 plug.
  
  Fig 2: Locating Transfer Case Straight Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE NO. 2 PLUG
1. Remove the No. 2 plug.
2. Remove the gasket from the No. 2 plug.
  
  Fig 3: Identifying Transfer Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRAIN PLUG
1. Remove the drain plug.
2. Remove the gasket from the drain plug.
  
  Fig 4: Identifying Transfer Drain Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE OIL SEAL LH
1. Using SST, tap out the oil seal from the case.
  SST 09308-00010
  
  NOTE: Do not damage the oil seal lip.
  
  Fig 5: Removing Transfer Case Oil Seal LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE OIL SEAL RH
1. Using SST, tap out the oil seal from the case.
  SST 09308-00010
  
  NOTE: Do not damage the oil seal lip.
  
  Fig 6: Removing Transfer Case Oil Seal RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT RING GEAR BACKLASH
1. Using a dial indicator, measure the backlash of the ring gear at 3 points.
  Standard backlash:
  
  0.10 to 0.20 mm (0.0039 to 0.0079 in.)
  
  If the backlash is not within the specified range, adjust the backlash or repair as necessary.
  
  Fig 7: Measuring Ring Gear Backlash
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TRANSFER CASE COVER
1. Remove the 8 bolts.
  
  Fig 8: Locating Transfer Case Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap out the cover from the case.
  
  Fig 9: Removing Transfer Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER RING GEAR
1. Remove the ring gear from the transfer case.
REMOVE TRANSFER CASE STRAIGHT PIN
1. Remove the 2 straight pins from the transfer case.
  
  Fig 10: Identifying Transfer Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT SHAFT
1. Remove the 5 bolts and output shaft.
  
  Fig 11: Locating Transfer Output Shaft Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, unstake the lock nut.
  SST 09930-00010
3. Remove the lock nut.
  
  Fig 12: Unstaking Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT REAR SHAFT SUB-ASSEMBLY
1. Using SST and a press, press out the shaft from the driven pinion.
  SST 09950-00020, 09950-60010 (09951-00220), 09950-70010 (09951-07100)
  
  Fig 13: Removing Transfer Output Rear Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVEN PINION FRONT BEARING
1. Using SST and a press, press out the driven pinion from the bearing.
  SST 09950-00020, 09950-60010 (09951-00220), 09950-70010 (09951-07100)
  
  Fig 14: Removing Transfer Driven Pinion Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the bearing.
  
  Fig 15: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT SHAFT WASHER
1. Remove the washer from the transfer pinion gear.
  
  Fig 16: Identifying Transfer Output Shaft Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RING GEAR MOUNTING CASE BEARING (for LH side)
1. Using SST, remove the bearing from the mounting case.
  SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00540)
  
  Fig 17: Removing Ring Gear Mounting Case Bearing (For LH Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the bearing.
  SST 09310-35010
REMOVE RING GEAR MOUNTING CASE WASHER

Fig 18: Tapping Out Ring Gear Mounting Case Bearing (For LH Side)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RING GEAR MOUNTING CASE BEARING (for RH side)
1. Using SST, remove the bearing from the mounting case.
  SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00540)
2. Using SST and a hammer, tap out the bearing (race) from the cover.
  SST 09636-20010
  
  Fig 19: Removing Ring Gear Mounting Case Bearing (For RH Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER RING GEAR MOUNTING CASE NO. 2 WASHER
REMOVE SHAFT SNAP RING
1. Using a snap ring expander, remove the snap ring.
  
  Fig 20: Removal/Installation Of Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER RING GEAR MOUNTING CASE
1. Using SST and a press, press out the ring gear from the mounting case.
  SST 09950-60010 (09951-00400)
  
  Fig 21: Identifying Transfer Ring Gear Mounting Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BREATHER OIL DEFLECTOR
1. Remove the 2 bolts and oil deflector.
  
  Fig 22: Identifying Breather Oil Deflector Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE BREATHER PLUG
1. Remove the breather plug from the transfer case.
  
  Fig 23: Locating Transfer Case Breather Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002