Transfer Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

REMOVE TRANSFER COVER GASKET
1. Remove the transfer cover gasket from the transfer assembly.
Fig 1: Locating Transfer Cover Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE BREATHER PLUG
1. Using a screwdriver and a hammer, remove the transfer case breather plug from the No. 1 transfer case cover.
NOTE: Be careful not to damage the contact surface of the No. 1 transfer case cover.

Fig 2: Locating Transfer Case Breather Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TRANSFER CASE COVER
1. Remove the 8 bolts.
  
  Fig 3: Locating No 1 Transfer Case Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and a hammer, remove the No. 1 transfer case cover from the transfer case.
NOTE: Be careful not to damage the contact surfaces of the case and cover.

Fig 4: Removing No. 1 Transfer Case Cover From Transfer Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BREATHER OIL DEFLECTOR
1. Remove the bolt and breather oil deflector from the No. 1 transfer case cover.
Fig 5: Locating Breather Oil Deflector Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DYNAMIC DAMPER
1. Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing sub-assembly.
REMOVE TRANSFER CASE STRAIGHT PIN
1. Remove the 4 transfer case straight pins from the transfer case.
REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT
1. Remove the 4 transfer and transaxle setting stud bolts.
Fig 6: Locating Transfer Dynamic Damper Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FIX TRANSFER ASSEMBLY
1. Fix the transfer assembly to the overhaul attachment.
REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR
1. Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.
Fig 7: Removing Transfer Extension Housing Dust Deflector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
1. Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing.
  SST 09308-00010
NOTE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.

Fig 8: Removing Transfer Extension Housing Type T Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 9: Locating Transfer Extension Housing Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case.
Fig 10: Removing Transfer Extension Housing Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PRELOAD
1. Using SST and a torque wrench, check the initial torque with the backlash range.
  SST 09326-20011
  
  Torque: 0.9 to 1.4 N*m (9 to 14 kgf*cm, 8.0 to 12.4 in.*lbf)
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
  
  Fig 11: Checking Initial Torque With Backlash Range
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.
  SST 09326-20011
  
  Torque: Preload
  
  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.).
REMOVE CENTER DIFFERENTIAL LOCK SLEEVE
1. Using snap ring pliers, remove the shaft snap ring.
  
  Fig 12: Removing Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the CTR differential lock sleeve.
  SST 09308-00010
Fig 13: Removing CTR Differential Lock Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE O-RING
1. Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.
NOTE: Be careful not to damage the lock sleeve's groove for the O-ring.

Fig 14: Removing O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE OIL SEAL
1. Using SST, remove the transfer case oil seal from the case.
  SST 09308-00010
NOTE: Be careful not to damage the oil-seal-fitted surface of the case.

Fig 15: Removing Transfer Case Oil Seal From Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER RH BEARING RETAINER OIL SEAL
1. Using SST, remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.
  SST 09308-00010
NOTE: Be careful not to damage the oil-seal-fitted surface of the retainer.

Fig 16: Removing Transfer RH Bearing Retainer Oil Seal
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 17: Locating Transfer RH Bearing Retainer Sub-Assembly With 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
3. Remove SST.
  
  Fig 18: Identifying Transfer RH Bearing Retainer Sub-Assembly And Transfer Case With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, remove the transfer RH bearing retainer sub-assembly from the transfer case.
  SST 09520-10021
Fig 19: Removing Transfer RH Bearing Retainer Sub-Assembly From Transfer Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE O-RING
1. Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assembly.
NOTE: Be careful not to damage the retainer's grooves for the O-rings.

Fig 20: Removing O-Rings From Transfer RH Bearing Retainer Sub-Assembly
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, No. 2 transfer ring gear mounting case washer and No. 2 transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.
  SST 09308-00010
NOTE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer sub-assembly.

Fig 21: Removing Center Differential Case Tapered Roller Bearing RH Outer Race
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SIDE GEAR SHAFT HOLDER BEARING
1. Using snap ring pliers, remove the side gear shaft holder hole snap ring.
2. Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assembly.
Fig 22: Removing Side Gear Shaft Holder Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER RING GEAR MOUNTING CASE
1. Remove the transfer ring gear mounting case from the transfer case.
REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
SST 09950-40011 (09951 -04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00430)

Fig 23: Removing Transfer Ring Gear Mounting Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST, remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
  NOTE: Apply grease to the screw thread and tip of SST before use.
  
  Fig 24: Removing Inner Race Of Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
  SST 09950-00020, 09950-00030, 09950-60010 (09951-00430)
  
  NOTE: Apply grease to the screw thread and tip of SST before use.
  
  Fig 25: Removing Roller And Remaining Inner Races Of Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
  SST 09950-40011 (09951 -04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
  
  NOTE: Apply grease to the screw thread and tip of SST before use.
  
  Fig 26: Removing Inner Race Of Center Differential Case Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
  SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)
NOTE: Apply grease to the screw thread and tip of SST before use.

Fig 27: Removing Roller And Remaining Inner Races Of Center Differential Case Tapered Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RING GEAR
1. Put matchmarks on the transfer ring gear mounting case and the ring gear.
2. Remove the 12 bolts.
  
  Fig 28: Identifying Matchmarks On Transfer Ring Gear Mounting Case And Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic hammer, remove the ring gear by tapping around its periphery.
NOTE: Do not damage the teeth of the ring gear.

Fig 29: Removing Ring Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER GEAR NUT
1. Using SST and a hammer, unstake the transfer gear nut.
  SST 09930-00010
  
  Fig 30: Unstaking Transfer Gear Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the transfer gear nut.
  SST 09326-20011,09556-16030
  
  Fig 31: Removing Transfer Gear Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer.
NOTE:
- Put shop cloths around the transfer case to help prevent the driven pinion from dropping out of the bearing.
- Place something like wooden blocks under the case to keep its level.
Fig 32: Identifying Driven Pinion, Transfer Driven Pinion Rear Bearing Inner Race And Transfer Pinion Bearing Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVEN PINION FRONT BEARING
1. Using SST and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.
  SST 09950-00020
Fig 33: Removing Transfer Driven Pinion Front Bearing Inner Race
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 positions to remove it from the transfer case.
REMOVE TRANSFER OUTPUT SHAFT WASHER
1. Remove the ring gear mounting case plate washer from the transfer case.
Fig 34: Removing Center Differential Case Tapered Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
1. Using a brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.
REMOVE RING GEAR MOUNTING CASE PLATE WASHER
1. Remove the transfer output washer from the transfer case.
Fig 35: Removing Center Differential Case Tapered Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVEN PINION REAR BEARING
1. Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.
Fig 36: Removing Transfer Driven Pinion Rear Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002