Transfer Assembly: Disassembly

WARNING: This page is about a different car, the 2007 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE BREATHER HOSE
REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR
1. Remove the bolt and driven gear.
REMOVE MOTOR ACTUATOR
1. Remove the 4 bolts and motor actuator.
  
  Fig 1: Removing 4 Bolts Of Motor Actuator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SCREW PLUG
1. Using a T40 "torx" socket, remove the screw plug.
REMOVE SPRING
1. Using a magnetic finger, remove the spring.
REMOVE BALL
1. Using a magnetic finger, remove the ball.
REMOVE TRANSFER INDICATOR SWITCH
1. Remove the 3 indicator switches and 3 gaskets.
  
  Fig 3: Removing Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
1. Remove the 6 bolts and extension housing.
  HINT:
  
  If necessary, tap the extension housing lightly with a plastic-faced hammer.
  
  Fig 4: Removing Front Transfer Extension Housing Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH SLEEVE WITH NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK

Fig 5: Removing Clutch Sleeve With No. 2 Shift Fork Shaft & No. 2 Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK
1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the No. 2 shift fork shaft.
2. Separate the No. 2 shift fork shaft and No. 2 shift fork.
  
  Fig 6: Tapping Out 3 Snap Rings From No. 2 Shift Fork Shaft Using Screwdrivers & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
1. Remove the 9 bolts and extension housing.
  HINT:
  
  If necessary, tap the extension housing lightly with a plastic-faced hammer.
REMOVE ADJUSTING SHIM
1. Remove the adjusting shims.
  
  Fig 7: Removing Rear Transfer Extension Housing Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER ASSEMBLY
1. Remove the 2 bolts and oil strainer.
  
  Fig 8: Removing Bolts & Oil Strainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CASE COVER
1. Remove the 5 bolts.
  
  Fig 9: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap the case cover and remove it.
  
  Fig 10: Tapping Case Cover Using Brass Bar & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE FRONT CASE AND REAR CASE
1. Using a snap ring expander, remove the snap ring from the rear case.
  
  Fig 11: Removing Snap Ring From Rear Case Using Snap Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 8 bolts.
3. Using a brass bar and hammer, tap the rear case and separate it.
  
  Fig 12: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING RACE
1. Remove the 2 bearing races from the rear case.
  
  Fig 13: Removing Bearing Races From Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT SUB-ASSEMBLY
1. Using a plastic-faced hammer, remove the input shaft from the front case.
  
  Fig 14: Removing Input Shaft Sub-Assembly From Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, NO. 1 SHIFT FORK SHAFT AND NO. 1 SHIFT FORK
1. Remove the idler gear with center differential, No. 1 shift fork shaft and No. 1 shift fork from the front case.
  
  Fig 15: Removing Idler Gear With Center Differential, No. 1 Shift Fork Shaft & No. 1 Shift Fork From Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE NO. 1 SHIFT FORK SHAFT AND NO. 1 SHIFT FORK
1. Using a pin punch and hammer, tap out the slotted spring pin.
2. Separate the No. 1 shift fork and No. 1 shift fork shaft.
  
  Fig 16: Tapping Out Slotted Spring Pin Using Pin Punch & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTER SHIFT LEVER AND INNER SHIFT LEVER
1. Remove the nut and washer from the outer shift lever.
2. Using a brass bar, hammer and socket wrench, tap out the lever lock pin.
3. Remove the outer shift lever, washer and inner shift lever from the front case.
  
  Fig 17: Tapping Out Lever Lock Pin Using Brass Bar, Hammer & Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INNER SHIFT LEVER OIL SEAL
1. Using a screwdriver, pry out the oil seal from the front case.
  
  Fig 18: Prying Out Oil Seal From Front Case Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT OIL SEAL
1. Using SST and a hammer, tap out the oil seal.
  SST 09316-60011 (09316-00011)
  
  Fig 19: Tapping Out Oil Seal Using SST & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL RECEIVER
1. Remove the bolt and oil receiver from the front case.
  
  Fig 20: Removing Bolt & Oil Receiver From Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING RACE
1. Using SST, remove the bearing race (for the idler gear).
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010), 09950-60010 (09951-00320)
  
  Fig 21: Removing Bearing Race (For Idler Gear) Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap out the bearing race (for the output shaft) from the front case.
  
  Fig 22: Tapping Out Bearing Race (For Output Shaft) From Front Case Using Brass Bar & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002