LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2016 >> 4Runner Limited, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 3 (Transfer Case (VF2CM) - Service Information) >> Transfer Assembly >> Disassembly [08/2019 - ] >> Procedure

Disassembly [08/2019 - ]: Procedure

WARNING: This page is about a different car, the 2024 Toyota 4Runner, 2023 Toyota 4Runner, 2022 Toyota 4Runner, 2021 Toyota 4Runner, and 2020 Toyota 4Runner. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE ACTUATOR BREATHER HOSE 
    1. GTY568131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disconnect the connection to the transfer shift actuator assembly, detach the 2 clamps, and then remove the actuator breather hose.

  2. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Remove the 4 bolts and transfer case cover sub-assembly.
      GTY708997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the breather oil deflector.
      GTY708995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Front Side) 
    1. Using a chisel and hammer, loosen the staked part of the transfer output shaft companion flange nut.
      NOTE:
      • Completely loosen the staked part of the lock nut when removing it.
      • Do not damage the threads of the driven sprocket.
    2. Using SST to hold the output shaft companion flange sub-assembly, remove the transfer output shaft companion flange nut.
      • SST: 09330-00021 
      GTY904463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
    3. Using SST, remove the output shaft companion flange sub-assembly.
      GTY907856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04031
        6. 09957-04010
        7. 09958-04011
      NOTE:

      Apply a lubricant to the threads and end of SST.

      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
    4. Using SST and hammer, remove the transfer output shaft companion flange oil seal.
      • SST: 09950-60011 
        1. 09951-00220
        2. 09951-00290
        3. 09952-06010
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

      Be careful not to damage the transfer output shaft companion flange oil seal and output shaft companion flange sub-assembly contact surfaces.

      GTY927589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSFER CASE OIL SEAL 

    See step  7

  5. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Rear Side) 
    1. Using a chisel and hammer, loosen the staked part of the transfer output shaft companion flange nut.
      NOTE:
      • Completely loosen the staked part of the transfer output shaft companion flange nut when removing it.
      • Do not damage the threads of the rear transfer output shaft.
    2. Using SST to hold the output shaft companion flange sub-assembly, remove the transfer output shaft companion flange nut and transfer output shaft O-ring.
      • SST: 09330-00021 
      GTY848925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
    3. Using SST, remove the output shaft companion flange sub-assembly.
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04031
        6. 09957-04010
        7. 09958-04011
      GTY854953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Apply a lubricant to the threads and end of SST.

      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
  6. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 

    See step  4

  7. REMOVE TRANSFER EXTENSION HOUSING 
    1. Remove the 5 bolts and transfer extension housing.

      HINT: 

      If necessary, tap the transfer extension housing with a plastic-faced hammer to remove it.

      GTY708987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSFER OUTPUT SHAFT WASHER 
    1. Remove the 2 transfer output shaft washers.
      GTY863894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Output Shaft Washer
      *2 No. 2 Transfer Output Shaft Spacer
    2. Remove the No. 2 transfer output shaft spacer.
  9. REMOVE NO. 1 TRANSFER CASE PLUG 
    1. Remove the No. 1 transfer case plug (filler plug) and No. 1 transfer case gasket.
      GTY866033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Transfer Case Plug (Filler Plug)
      *2 No. 1 Transfer Case Gasket
      *3 Transfer Drain Plug
      *4 Transfer Drain Plug Gasket
    2. Remove the transfer drain plug and transfer drain plug gasket.
  10. REMOVE REAR TRANSFER CASE 
    1. Remove the 12 bolts and 4 brackets.
      GTY869130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bracket
    2. Remove the rear transfer case.

      HINT: 

      If necessary, tap the rear transfer case with a plastic-faced hammer to remove it.

  11. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Remove the 3 bolts and transfer oil separator sub-assembly.
      GTY709021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the transfer case magnet.
  12. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Remove the 3 bolts and transfer oil pump body sub-assembly.
      GTY709025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the transfer oil pump body O-ring.
      TEXT IN ILLUSTRATION

      *a Protective Tape
      GTY894581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the transfer oil pump body sub-assembly.

      HINT: 

      Tape the screwdriver tip before use.

    3. Remove the transfer oil pump gear.
      GTY709004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSFER FRONT BEARING RETAINER SUB-ASSEMBLY 
    1. Remove the 5 bolts and transfer front bearing retainer sub-assembly.
      GTY708996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If necessary, tap the transfer front bearing retainer sub-assembly with a plastic-faced hammer to remove it.

  14. REMOVE TRANSFER FRONT BEARING TYPE T OIL SEAL 
    1. Using a screwdriver and hammer, remove the transfer front bearing type T oil seal.
      TEXT IN ILLUSTRATION

      *a Protective Tape
      NOTE:

      Be careful not to damage the transfer front bearing type T oil seal and transfer front bearing retainer sub-assembly contact surfaces.

      HINT: 

      Tape the screwdriver tip before use.

      GTY939453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSFER LOW PLANETARY GEAR ASSEMBLY 
    1. Using a snap ring expander, remove the transfer low planetary gear bearing shaft snap ring.
      GTY709007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the transfer low planetary gear assembly with the transfer input shaft.
      GTY709008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE TRANSFER CASE PLUG 
    1. Remove the transfer case plug, transfer case compression spring and pin.
      GTY907911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Case Plug
      *2 Transfer Case Compression Spring
      *3 Pin
  17. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    1. Using a screwdriver, remove the transfer low planetary ring gear hole snap ring.
      TEXT IN ILLUSTRATION

      *a Protective Tape
      GTY913524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the front transfer case.

      HINT: 

      Tape the screwdriver tip before use.

    2. Remove the transfer low planetary ring gear.
  18. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, remove the transfer low planetary gear shaft snap ring.
      TEXT IN ILLUSTRATION

      *a Protective Tape
      GTY920145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the transfer low planetary gear assembly.

      HINT: 

      Tape the screwdriver tip before use.

    2. Remove the transfer low planetary gear spline piece.
      GTY709012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the transfer output shaft front needle roller bearing.
      GTY709009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE TRANSFER INPUT SHAFT 
    1. Using a snap ring expander, remove the transfer input gear stopper shaft snap ring.
      GTY735847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the transfer input gear stopper and transfer input gear stopper ball.
      GTY869180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Input Gear Stopper
      *2 Transfer Input Gear Stopper Ball
      *3 Manual Transfer Planetary Carrier Washer
    3. Remove the manual transfer planetary carrier washer.
    4. Remove the transfer input shaft, transfer low planetary gear bearing and No. 1 transfer thrust bearing race.
      GTY871497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Input Shaft
      *2 Transfer Low Planetary Gear Bearing
      *3 No. 1 Transfer Thrust Bearing Race
  20. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    1. Remove the 2 No. 1 transfer input shaft seal rings.
      GTY735857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSFER INPUT SHAFT BEARING 
    1. Using a snap ring expander, remove the transfer input bearing shaft snap ring.
      GTY709063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the transfer input shaft bearing.
      • SST: 09555-55010 
      • SST: 09950-00030 
      • SST: 09950-60021 
        1. 09951-00630
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
      GTY886395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the transfer low planetary gear assembly.
      • Apply a lubricant to the threads and end of SST.
  22. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    1. Using SST, remove the transfer low planetary gear bearing.
      GTY892706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09527-10011 
      • SST: 09612-65014 
        1. 09612-01050
        2. 09612-01060
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
      NOTE:

      Hook SST securely between the bearing and transfer low planetary gear.

  23. REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT 
    NOTE:
    • When using a vise, place aluminum plates between the part and vise.
    • When using a vise, do not overtighten it.
    1. Type A:
      GTY1179211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Type A
      *B Type B
      *1 Shift Detent Ball Spring Plug
      *2 Shift Detent Ball Compression Spring
      *3 Shift Detent Ball
      1. Using a 6 mm hexagon wrench, remove the 2 shift detent ball spring plugs.
    2. Type B:
      1. Remove the 2 shift detent ball spring plugs.
    3. Using a magnet hand, remove the 2 shift detent ball compression springs and 2 shift detent balls.
    4. Using 2 screwdrivers and a hammer, remove the 2 transfer gear shift fork shaft snap rings.
      GTY568032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Use a piece of cloth to prevent the transfer gear shift fork shaft snap rings from flying off.

    5. Remove the bolt and transfer shift shaft stopper.
      GTY708993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. To remove the transfer front drive shift fork shaft, shift the No. 1 transfer gear shift fork and No. 2 transfer gear shift fork to the positions shown in the illustration.
      GTY936782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Front Drive Shift Fork Shaft
      *2 No. 1 Transfer Gear Shift Fork
      *3 No. 2 Transfer Gear Shift Fork
    7. Remove the transfer front drive shift fork shaft.
    8. Using a magnet hand, remove the 2 shift interlock pin or rollers.
      GTY709015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REAR TRANSFER OUTPUT SHAFT, TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVEN SPROCKET 
    NOTE:
    • When using a vise, place aluminum plates between the part and vise.
    • When using a vise, do not overtighten it.
    1. Using 2 screwdrivers and a hammer, remove the transfer gear shift fork shaft snap ring.

      HINT: 

      • Use a piece of cloth to prevent the transfer gear shift fork shaft snap ring from flying off.
      • Remove only the transfer gear shift fork shaft snap ring on the front side of the transfer shift actuator shaft.
      GTY568067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, remove the transfer output shaft - shaft snap ring.
      GTY735849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic-faced hammer, carefully tap the rear transfer case, and remove the transfer output shaft rear, transfer driven sprocket and transfer front drive chain with the No. 1 transfer gear shift fork and No. 2 transfer gear shift fork.
      GTY709018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY 
    1. Using 2 screwdrivers and a hammer, remove the transfer gear shift fork shaft snap ring.
      GTY568066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Use a piece of cloth to prevent the transfer gear shift fork shaft snap ring from flying off.

    2. Remove the 3 bolts and transfer shift actuator assembly.
      GTY709022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    1. for Front Side:

      Using SST and a press, remove the transfer driven sprocket bearing.

      • SST: 09555-55010 
      • SST: 09950-60011 
        1. 09951-00210
      • SST: 09950-70010 
        1. 09951-07100
      GTY854257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to drop or damage the driven sprocket.

    2. for Rear Side:

      Using SST and a press, remove the transfer driven sprocket bearing.

      GTY860212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09555-55010 
      • SST: 09950-60011 
        1. 09951-00270
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

      Be careful not to drop or damage the driven sprocket.

  27. REMOVE TRANSFER CLUTCH HUB 
    1. Remove the transfer high and low clutch sleeve.
    2. Using a snap ring expander, remove the transfer clutch hub shaft snap ring.
      GTY709068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, remove the transfer clutch hub.
      GTY909815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09527-10011 
      NOTE:

      Be careful not to drop or damage the rear transfer output shaft.

  28. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
    1. Using SST and a press, remove the rear transfer output shaft radial ball bearing.
      GTY913206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09555-55010 
      NOTE:

      Be careful not to drop or damage the rear transfer output shaft.

    2. Remove the No. 1 transfer output shaft spacer.
      GTY846949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Transfer Output Shaft Spacer
      *2 Needle Roller Bearing
      *3 Transfer Drive Sprocket Sub-assembly
    3. Remove the needle roller bearing.
    4. Remove the transfer drive sprocket sub-assembly.
  29. REMOVE TRANSFER SYNCHRONIZER RING SET (w/ A.D.D.) 
    1. Remove the transfer synchronizer ring set.
      GTY568072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FRONT DRIVE CLUTCH SLEEVE 
    1. GTY859043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the front drive clutch sleeve.

      TEXT IN ILLUSTRATION

      *1 Front Drive Clutch Sleeve
      *2 Transfer Synchromesh Shifting Key Spring
      *3 No. 1 Synchromesh Shifting Key
      NOTE:

      w/ A.D.D.:

      Be careful not to drop the 3 No. 1 synchromesh shifting keys.

    2. w/ A.D.D.:

      Remove the 2 transfer synchromesh shifting key springs and 3 No. 1 synchromesh shifting keys.

  31. REMOVE TRANSFER DRIVE CLUTCH HUB 
    1. Using SST and a press, remove the transfer drive clutch hub.
      • SST: 09527-10011 
      NOTE:

      Be careful not to drop or damage the rear transfer output shaft.

      GTY862805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals