Transfer Assembly: Reassembly

INSTALL TRANSFER DRIVEN PINION REAR BEARING
1. Using SST and a press, install the transfer driven pinion rear bearing outer race to the transfer case.
  SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
  
  NOTE: Place something like wooden blocks under the case to keep its level.
  
  Fig 1: Using SST & Press To Install Transfer Driven Pinion Rear Bearing Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER OUTPUT SHAFT WASHER
1. Install the transfer output shaft washer to the transfer case.
  HINT:
  
  Reuse the washer.
INSTALL TRANSFER DRIVEN PINION FRONT BEARING
1. Install the transfer driven pinion front bearing outer race to the transfer case with SST, bolt and nut.
  SST 09316-60011 (09316-00061), 09950-60020 (09951-00750, 09951-00770, 09951-00810)
  
  Fig 2: Identifying Transfer Driven Pinion Front Bearing Outer Race & Transfer Case With SST, Bolt & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RING GEAR MOUNTING CASE PLATE WASHER
1. Install the ring gear mounting case plate washer to the transfer case.
  HINT:
  
  Reuse the washer.
INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using SST and a press, install the center differential case tapered roller bearing LH outer race to the transfer case.
  SST 09950-60020 (09951-00680), 09950-70010 (09951-07200)
  
  SST 09950-70010 (09951-07200)
  
  Fig 3: Using SST & Press To Install Center Differential Case Tapered Roller Bearing LH Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DRIVEN PINION FRONT BEARING
1. Using SST and a press, install the transfer driven pinion front bearing inner race to the driven pinion.
  SST 09316-60011 (09316-00041)
  
  Fig 4: Using SST & Press To Install Transfer Driven Pinion Front Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVEN PINION
1. Install the driven pinion to the transfer case.
  
  Fig 5: Identifying Driven Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new transfer pinion bearing spacer and a new transfer driven pinion rear bearing inner race to the driven pinion.
  
  Fig 6: Identifying Transfer Pinion Bearing Spacer & Transfer Driven Pinion Rear Bearing Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, tighten a new transfer gear nut (at a standard torque.).
  SST 09326-20011, 09556-16030
  
  Torque: 277 to 378 N*m (2820 to 3855 kgf*cm, 204 to 279 ft.*lbf)
  
  NOTE: Do not stake the transfer gear nut.
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 750 mm (29.53 in.).
  
  Fig 7: Tightening New Transfer Gear Nut Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT AND ADJUST DRIVEN PINION PRELOAD
1. Using SST and a torque wrench, measure the initial torque of the driven pinion.
  SST 09326-20011
  
  Torque: New bearing
  
  1.1 to 1.6 N*m (10 to 16 kgf*cm, 9.7 to 14.2 in.*lbf)
  
  Used bearing
  
  0.9 to 1.4 N*m (9 to 14 kgf*cm, 8.0 to 12.4 in.*lbf)
  
  Fig 8: Measuring Initial Torque Of Driven Pinion Using SST & Torque Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
  
  NOTE: Measure the preload after rotating the bearing both clockwise and counterclockwise to make it fit.
2. If the preload is too large, replace the transfer pinion bearing spacer with a new one.
3. If the preload is too small, repeatedly adjust the preload by tightening the transfer gear nut 5 to 10 degrees at a time until the standard value is obtained.
4. If the preload is insufficient, even though the tightening torque of the transfer gear nut exceeds the maximum of the standard value, loosen the transfer gear nut and apply gear oil SAE 90 (GL-5) to the transfer gear nut and the screw thread and the base of the driven pinion. And then repeat the preceding operation. If the tightening torque is bearing spacer with a new one and adjust it.
  Torque: 378 N*m (3855 kgf*cm, 279 ft.*lbf)
INSTALL RING GEAR
1. Heat the ring gear in boiling water from 90 to 100°C (194 to 212°F).
  
  Fig 9: Heating Ring Gear In Boiling Water
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Completely remove grease and moisture on the contact surfaces of the ring gear and the transfer ring gear mounting case.
3. Align the matchmarks on the ring gear and transfer ring gear mounting case and quickly assemble them.
4. Tighten the 12 bolts.
  Torque: 78 N*m (790 kgf*cm, 57 ft.*lbf)
  NOTE:
  - Tighten the bolts in diagonal order in splitting several times.
  - After the ring gear has well cooled down, fully tighten the bolts.
  - Make the bolt heads in order to check if they are retightened or not.
  Fig 10: Aligning Matchmarks On Ring Gear & Transfer Ring Gear Mounting Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using SST and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case.
  SST 09506-35010, 09950-60010 (09951-00430), 09223-00010
  
  NOTE: When replacing the inner race, replace it together with the outer race.
  
  Fig 11: Using SST & Press To Install Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER RING GEAR MOUNTING CASE
1. Install the transfer ring gear mounting case to the transfer case.
  NOTE: Damage to the spline, the bearing's rotating surface and gear face may cause a decrease in their strength. Care should be taken when installing them.
  
  Fig 12: Identifying Transfer Ring Gear Mounting Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER
1. Install the No. 2 transfer ring gear mounting case washer to the transfer RH bearing retainer sub-assembly.
  HINT:
  
  Reuse the washer.
INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using SST and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer sub - assembly.
  SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
  
  Fig 13: Using SST & Press To Install Center Differential Case Tapered Roller Bearing RH Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY
1. Place the transfer with the surface where the transfer RH bearing retainer sub-assembly is facing up.
  
  Fig 14: Identifying Transfer RH Bearing Retainer Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the centers of the transfer ring gear mounting case and the transfer case.
3. Insert SST into the transfer RH bearing retainer sub-assembly.
  SST 09387-00090
  
  Fig 15: Inserting SST Into Transfer RH Bearing Retainer Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. With SST and the transfer RH bearing sub-assembly in close contact, install the transfer RH bearing retainer sub-assembly together with SST into the transfer case.
  NOTE: Avoid interference between the case and the retainer, and between SST and the transfer ring gear mounting case.
  
  HINT:
  
  If the engagement is tight, tap SST with a hammer placing a brass bar on the center of SST.
5. Make sure that the transfer RH bearing retainer sub-assembly and transfer case contact closely.
  
  Fig 16: Placing Brass Bar On Center Of SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the 7 bolts evenly in order shown below.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  Fig 17: Identifying Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove SST.
  
  Fig 18: Identifying SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT DIFFERENTIAL RING GEAR BACKLASH

Set the dial gauge perpendicular to the ring gear face, fix the driven pinion, and check backlash by moving the ring gear.
Backlash: 0.08 to 0.15 mm (0.0031 to 0.0059 in.)

NOTE: Measure it at 3 points or more on the ring gear periphery.

Fig 19: Measuring Differential Ring Gear Backlash Using Dial Gauge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the measured value is out of standard, select a proper washer for the center differential case tapered roller bearing on the LH side from the table below and install it to obtain the standard value.

WASHER THICKNESS SPECIFICATION TABLE

Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
AA	2.07 (0.0814)	AB	2.10 (0.0826)	AC	2.13 (0.0838)
BA	2.16 (0.0850)	BB	2.19 (0.0862)	BC	2.22 (0.0874)
CA	2.25 (0.0885)	CB	2.28 (0.0897)	CC	2.31 (0.0909)
DA	2.34 (0.0921)	DB	2.37 (0.0933)	DC	2.40 (0.0944)
EA	2.43 (0.0956)	EB	2.46 (0.0968)	EC	2.49 (0.0980)
FA	2.52 (0.0992)	FB	2.55 (0.1003)	FC	2.58 (0.1015)
GA	2.61 (0.1027)	GB	2.64 (0.1039)	GC	2.67 (0.1051)
HA	2.70 (0.1062)	HB	2.73 (0.1074)	HC	2.76 (0.1086)
JA	2.79 (0.1098)	JB	2.82 (0.1110)	JC	2.85 (0.1122)
KA	2.88 (0.1133)	KB	2.91 (0.1145)	KC	2.94 (0.1157)
LA	2.97 (0.1169)	LB	3.00 (0.1181)	-	-

HINT:

When the backlash is larger or smaller than the standard, select a thinner or thicker washer respectively.

Ring gear mounting case plate washer location is shown below.

Fig 20: Identifying Ring Gear Mounting Case Plate Washer Location
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

Apply Prussian blue thinly and uniformly to both faces of the ring gear and rotate it several times.
NOTE: Check the tooth contact on the ring gear at 4 places or more.

Fig 21: Checking Tooth Contact Between Ring Gear & Drive Pinion
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Observe the pattern shown by Prussian blue.

Fig 22: Identifying Tooth Contact Pattern
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

In case of poor tooth contact, select a washer for the driven pinion bearing front side from the following table and replace it.

NOTE: If the washer thickness is changed, the backlash will be also changed.

WASHER THICKNESS SPECIFICATION TABLE

Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
AA	1.20 (0.0472)	AC	1.22 (0.0480)	BB	1.24 (0.0488)
CA	1.26 (0.0496)	CC	1.28 (0.0503)	DB	1.30 (0.0511)
EA	1.32 (0.0519)	EC	1.34 (0.0527)	FB	1.36 (0.0535)
GA	1.38 (0.0543)	GC	1.40 (0.0551)	HB	1.42 (0.0559)
JA	1.44 (0.0566)	JC	1.46 (0.0574)	KB	1.48 (0.0582)
LA	1.50 (0.0590)	LC	1.52 (0.0598)	MB	1.54 (0.0606)
NA	1.56 (0.0614)	NC	1.58 (0.0622)	PB	1.60 (0.0629)
QA	1.62 (0.0637)	QC	1.64 (0.0645)	-	-

The location of the transfer output washer for tooth contact adjustment is shown below.

Fig 23: Identifying Transfer Output Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST TOTAL PRELOAD

Using SST and a torque wrench, measure the initial torque with the driven pinion bearing contact with the ring gear face.
SST 09326-20011

Torque: New bearing

1.3 to 1.98 N*m (13.3 to 20.2 kgf*cm, 11.5 to 17.5 in.*lbf)

Used bearing

1.07 to 1.68 N*m (10.9 to 17.1 kgf*cm, 9.5 to 14.9 in.*lbf)

Fig 24: Using SST & Torque Wrench To Measure Initial Torque
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Before measurement, rotate the bearing in both directions several times to make it fit.

HINT:

Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).

If the value is out of standard range, select the washer for the center differential case tapered roller bearing RH side from the following table and replace it.

WASHER THICKNESS SPECIFICATION TABLE

Mark	Washer Thickness mm (in:)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
AA	1.47 (0.0578)	AB	1.50 (0.0590)	AC	1.53 (0.0602)
BA	1.56 (0.0614)	BB	1.59 (0.0625)	BC	1.62 (0.0637)
CA	1.65 (0.0649)	CB	1.68 (0.0661)	CC	1.71 (0.0673)
DA	1.74 (0.0685)	DB	1.77 (0.0696)	DC	1.80 (0.0708)
EA	1.83 (0.0720)	EB	1.86 (0.0732)	EC	1.89 (0.0744)
FA	1.92 (0.0755)	FB	1.95 (0.0767)	FC	1.98 (0.0779)
GA	2.01 (0.0790)	GB	2.04 (0.0803)	GC	2.07 (0.0814)
HA	2.10 (0.0826)	HB	2.13 (0.0838)	HC	2.16 (0.0850)
JA	2.19 (0.0862)	JB	2.22 (0.0874)	JC	2.25 (0.0885)
KA	2.28 (0.0897)	KB	2.31 (0.0909)	KC	2.34 (0.0921)
LA	2.37 (0.0933)	LB	2.40 (0.0944)	LC	2.43 (0.0956)
MA	2.46 (0.0968)	MB	2.49 (0.0980)	MC	2.52 (0.0992)
NA	2.55 (0.1003)	NB	2.58 (0.1015)	-	-

The location of the No. 2 transfer ring gear mounting case washer for preload adjustment is shown below.

Fig 25: Identifying No. 2 Transfer Ring Gear Mounting Case Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a chisel, stake the transfer gear nut.

Fig 26: Staking Transfer Gear Nut Using Chisel
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY
1. Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.
  
  Fig 27: Identifying Transfer RH Bearing Retainer Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, make a clearance between the transfer RH bearing retainer sub-assembly and the transfer case.
  SST 09950-00020
  
  Fig 28: Using SST To Make Clearance Between Transfer RH Bearing Retainer Sub-Assembly & Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove SST.
4. Using SST, remove the transfer RH bearing retainer sub-assembly from the transfer case.
  SST 09520-10021
  
  Fig 29: Using SST To Remove Transfer RH Bearing Retainer Sub-Assembly From Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Fix the transfer RH bearing retainer sub-assembly in a vise.
2. Using SST, remove the center differential case tapered roller bearing RH outer race and transfer ring gear mounting case washer No. 2 from the transfer RH bearing retainer sub-assembly.
  SST 09308-00010
  
  Fig 30: Using SST To Remove Center Differential Case Tapered Roller Bearing RH Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SIDE GEAR SHAFT HOLDER BEARING
1. Install the side gear shaft holder bearing to the transfer RH bearing retainer sub-assembly.
2. Using snap ring pliers, install the side gear shaft holder hole snap ring.
  HINT:
  
  Check that the side gear shaft holder hole snap ring fits in the groove of the transfer RH bearing retainer sub-assembly.
  
  Fig 31: Using Snap Ring Pliers To Install Side Gear Shaft Holder Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
1. Using SST and a press, install the No. 2 transfer RH bearing retainer oil seal to the transfer RH bearing retainer sub-assembly.
  SST 09950-60010 (09951-00350, 09951-00540, 09952-06010), 09950-70010 (09951-07150)
  
  NOTE: Carefully press-fit so that the oil seal will not be tilted.
  
  Fig 32: Using SST & Press To Install No. 2 Transfer RH Bearing Retainer Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply small amount of MP grease No. 2 to the oil seal lip.
INSTALL NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER
1. Install the No. 2 transfer ring gear mounting washer to the transfer RH bearing retainer sub-assembly.
INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using SST and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer sub-assembly.
  SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
  
  Fig 33: Using SST & Press To Install Center Differential Case Tapered Roller Bearing RH Outer Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL O-RING
1. Coat 2 new O-rings with hypoid gear oil.
2. Install the 2 new O-rings to the transfer RH bearing retainer sub-assembly.
  NOTE: Be careful not to twist the O-ring and fit it properly in the retainer's groove.
  
  Fig 34: Identifying New Transfer RH Bearing Retainer Sub-Assembly O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY
1. Place the transfer with the surface where the transfer RH bearing retainer sub-assembly is facing up.
2. Align the centers of the transfer ring gear mounting case and the transfer case.
3. Apply MP grease No. 2 thinly to area A as shown below.
  HINT:
  
  Apply MP grease No. 2 to prevent the oil seal lip from rolling back.
  
  Fig 35: Identifying MP Grease No. 2 Applying Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert SST into the transfer RH bearing retainer sub-assembly.
  SST 09387-00090
  
  NOTE: Insert SST straight in order not to damage the oil seal.
  
  Fig 36: Inserting SST Into Transfer RH Bearing Retainer Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. With SST and the transfer RH bearing sub-assembly in close contact, install the transfer RH bearing retainer sub-assembly together with SST into the transfer case.
  NOTE:
  - Avoid interference between the case and the retainer, and between SST and the transfer ring gear mounting case.
  - Carefully check the retainer's O-ring for damage and incorrect fitting.
  HINT:
  - If the engagement is tight, tap SST with a hammer placing a brass bar on the center of SST.
    
    Fig 37: Placing Brass Bar On Center Of SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - If SST and retainer are not in close contact, the seal for the inner end of the retainer may not be properly aligned when the retainer goes into position. This may result in the lip of the oil seal being rolled back during installation.
  - If SST and retainer are not in close contact, the center of the retainer or transfer ring gear mounting case may come out of position when the retainer is being installed. This can cause the lip of the oil seal to be rolled back.
6. Make sure that the transfer RH bearing retainer sub-assembly and transfer case contact closely.
7. Tighten the 7 bolts evenly in order shown below.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  Fig 38: Identifying Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove SST.
  
  Fig 39: Identifying SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TOTAL PRELOAD
1. Using SST(s) and a torque wrench, measure the initial torque with the driven pinion being in contact with the ring gear face.
  SST 09326-20011
  
  Torque: New bearing
  
  1.3 to 1.98 N*m (13.3 to 20.2 kgf*cm, 11.5 to 17.5 in.*lbf)
  
  Used bearing
  
  1.07 to 1.68 N*m (10.9 to 17.1 kgf*cm, 9.5 to 14.9 in.*lbf)
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
  
  Fig 40: Using SST & Torque Wrench To Measure Initial Torque With Driven Pinion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
1. Using SST, install the transfer RH bearing retainer oil seal to the transfer RH bearing retainer sub-assembly to the position as shown below.
  SST 09223-46011
  NOTE:
  - Do not install the oil seal obliquely.
  - Do not damage the oil seal lip.
2. Apply MP grease to the oil seal lip.
  
  Fig 41: Using SST To Install Transfer RH Bearing Retainer Oil Seal To Transfer RH Bearing Retainer Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE OIL SEAL
1. Using SST, install the transfer case oil seal to the transfer case at the position as shown below.
  SST 09387-00010, 09950-70010 (09951-07150)
  NOTE:
  - Do not install the oil seal obliquely.
  - Do not damage the oil seal lip.
  Fig 42: Using SST To Install Transfer Case Oil Seal To Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply small amount of MP grease to the oil seal lip.
INSTALL CTR DIFFERENTIAL LOCK SLEEVE
1. Coat a new O-ring with hypoid gear oil.
2. Install the O-ring to the CTR differential lock sleeve.
  NOTE: Be careful not to twist the O-ring and fit it properly in the retainer's groove.
  
  Fig 43: Identifying CTR Differential Lock Sleeve O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, install the CTR differential lock sleeve to the transfer case.
  SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)
  
  Fig 44: Using SST To Install CTR Differential Lock Sleeve To Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using snap ring pliers, install the shaft snap ring.
  NOTE: Check that the snap ring is fitted in the groove of the ring gear mounting case.
  
  Fig 45: Using Snap Ring Pliers To Install Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
1. Using SST, install the transfer extension housing type T oil seal to the transfer extension housing at the position as shown below.
  SST 09950-60010 (09951-00380, 09951-00580, 09951-07150, 09952-06010), 09950-70010
  NOTE:
  - Do not install the oil seal obliquely.
  - Do not damage the oil seal lip.
  Fig 46: Using SST To Install Transfer Extension Housing Type T Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply small amount of MP grease No. 2 to the oil seal lip.
INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR
1. Using SST and press, install a new transfer extension housing dust deflector to the transfer extension housing sub-assembly.
  SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
  
  Fig 47: Using SST & Press To Install New Transfer Extension Housing Dust Deflector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
1. Apply sealant 1281 to the transfer extension housing sub-assembly in a continuous bead of 1.2 mm diameter as shown below.
  NOTE:
  - Wipe any grease off from the attaching surfaces.
  - Install the transfer extension housing sub-assembly within 10 minutes after applying the sealant.
  Fig 48: Applying Sealant To Transfer Extension Housing Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transfer extension housing sub-assembly to the transfer case with the 4 bolts.
  Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
  
  Fig 49: Identifying Transfer Extension Housing Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the transfer assembly from the overhaul attachment.
INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT
1. Install the transfer and transaxle setting stud bolts to the parts of the transfer case as shown below.
  Torque: 39 N*m (400 kgf*cm, 30 ft.*lbf)
  
  NOTE: Install the sealant-coated side of the transfer and transaxle stud bolt to the transfer case.
  
  Fig 50: Identifying Transfer & Transaxle Setting Stud Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE STRAIGHT PIN
1. Using a plastic hammer, install the 4 transfer case straight pins to the transfer case as shown below.
  
  Fig 51: Identifying Transfer Case Straight Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DYNAMIC DAMPER
1. Install the transfer dynamic damper to the transfer extension housing sub-assembly with the 3 bolts.
  Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
  
  Fig 52: Identifying Transfer Extension Housing Sub-Assembly With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BREATHER OIL DEFLECTOR
1. Install the breather oil deflector to the No. 1 transfer case cover with the bolt.
  Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)
  
  NOTE: Be careful about the direction of the deflector's fold.
  
  Fig 53: Identifying Breather Oil Deflector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSFER CASE COVER
1. Apply sealant 1281 to the No. 1 transfer case cover in a continuous bead of 1.2 mm diameter as shown below.
  NOTE:
  - Wipe any grease off from the attaching surfaces.
  - Install the No. 1 transfer case cover within 10 minutes after applying the sealant.
  Fig 54: Applying Sealant To No. 1 Transfer Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 transfer case cover to the transfer case with the 8 bolts.
  Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
  
  Fig 55: Identifying No. 1 Transfer Case Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE BREATHER PLUG
1. Using SST and a hammer, install the transfer case breather plug to the No. 1 transfer case cover.
  SST 09612-10093 (09612-10061)
  
  Fig 56: Using SST & Hammer To Install Transfer Case Breather Plug To No. 1 Transfer Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER COVER GASKET
1. Install a new transfer cover gasket to the transfer case.
  
  Fig 57: Identifying New Transfer Cover Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002