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Reassembly [08/2019 - ]: Procedure

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  1. INSTALL TRANSFER DRIVE CLUTCH HUB 
    1. Using SST and a press, install a new transfer drive clutch hub.
      • SST: 09527-10011 
      GTY869001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When replacing the transfer drive clutch hub, replace it with a new one and align it with the rear transfer output shaft.
      • Make sure the transfer drive clutch hub contacts the edge of the rear transfer output shaft, but do not press it in more than necessary.
  2. INSTALL FRONT DRIVE CLUTCH SLEEVE 
    1. w/ A.D.D.:
      1. Install the front drive clutch sleeve.
        GTY872307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Install the front drive clutch sleeve in the correct direction.

        TEXT IN ILLUSTRATION

        *1 Front Drive Clutch Sleeve
        *2 Transfer Synchromesh Shifting Key Spring
        *3 No. 1 Synchromesh Shifting Key
        *a CORRECT
        *b INCORRECT
        Rear Side
      2. Install the 2 transfer synchromesh shifting key springs and 3 No. 1 synchromesh shifting keys.
        NOTE:
        • Install the shifting key springs so that their openings do not overlap as shown in the illustration.
        • Install the No. 1 synchromesh shifting keys so that they are securely attached to the 2 transfer synchromesh shifting key springs.
        • Install the No. 1 synchromesh shifting keys so that they do not rest on the ends of the transfer synchromesh shifting key springs as shown in the illustration.
        • Make sure that the transfer synchromesh shifting key springs are firmly connected to the No. 1 synchromesh shifting key.
        • Make sure that the front drive clutch sleeve moves smoothly.
    2. w/o A.D.D.:
      GTY907008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the front drive clutch sleeve.

      NOTE:

      Install the front drive clutch sleeve in the correct direction.

      TEXT IN ILLUSTRATION

      Rear Side
  3. INSTALL TRANSFER SYNCHRONIZER RING SET (w/ A.D.D.) 
    NOTE:

    Be careful not to drop the front drive clutch sleeve and No. 1 synchromesh shifting key.

    1. Apply transfer oil to the transfer synchronizer ring set.
    2. Install the transfer synchronizer ring set.
      GTY604081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Align the key groove of the transfer synchronizer ring set with the No. 1 synchromesh shifting key, and then install the transfer synchronizer ring set.

  4. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
    NOTE:
    • w/ A.D.D.:

      Be careful not to drop the front drive clutch sleeve and No. 1 synchromesh shifting key.

    • w/o A.D.D.:

      Be careful not to drop the front drive clutch sleeve.

    1. Apply transfer oil to the rolling and thrusting surfaces of the needle roller bearing, and the fitting surfaces of the transfer drive sprocket sub-assembly and front drive clutch sleeve.
      TEXT IN ILLUSTRATION

      *1 Transfer Drive Sprocket Sub-assembly
      *2 Needle Roller Bearing
      *3 No. 1 Transfer Output Shaft Spacer
    2. Install the transfer drive sprocket sub-assembly.
      GTY881123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the needle roller bearing.
    4. Install the No. 1 transfer output shaft spacer.
    5. GTY884876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Apply transfer oil to a new rear transfer output shaft radial ball bearing and the press-fit portion of the rear transfer output shaft.

      TEXT IN ILLUSTRATION

      Rear Side
    6. Using SST and a press, install the rear transfer output shaft radial ball bearing.
      • SST: 09316-60012 
        1. 09316-00011
        2. 09316-00051
      NOTE:
      • Install the rear transfer output shaft radial ball bearing with the installation groove of the transfer output shaft snap ring facing the rear side as shown in the illustration.
      • Make sure the rear transfer output shaft radial ball bearing contacts the edge of the No. 1 transfer output shaft spacer, but do not press it in more than necessary.
      • Make sure that the transfer drive sprocket sub-assembly moves smoothly.
    7. Measure the transfer drive sprocket sub-assembly thrust clearance.

      See step  3

  5. INSTALL TRANSFER CLUTCH HUB 
    NOTE:
    • w/ A.D.D.:

      Be careful not to drop the front drive clutch sleeve and No. 1 synchromesh shifting key.

    • w/o A.D.D.:

      Be careful not to drop the front drive clutch sleeve.

    1. Apply transfer oil to the transfer clutch hub and the press-fit portion of the rear transfer output shaft.
    2. Using SST and a press, install the transfer clutch hub.
      • SST: 09527-10011 
      TEXT IN ILLUSTRATION

      Rear Side
      GTY890779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the transfer clutch hub in the correct direction.
      • Make sure the transfer clutch hub contacts the edge of the rear transfer output shaft, but do not press it in more than necessary.
    3. Select a transfer clutch hub shaft snap ring from the table below so that the clearance between the transfer clutch hub and transfer clutch hub shaft snap ring is 0.15 mm (0.00590 in.) or less.
      GTY709068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Snap Ring Thickness

      Part No. Specified Condition
      90520-39013 2.00 to 2.05 mm (0.0788 to 0.0807 in.)
      90520-39014 2.05 to 2.10 mm (0.0808 to 0.0826 in.)
      90520-39004 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      90520-39005 2.15 to 2.20 mm (0.0847 to 0.0866 in.)
      90520-39006 2.20 to 2.25 mm (0.0867 to 0.0885 in.)
      90520-39007 2.25 to 2.30 mm (0.0886 to 0.0905 in.)
      90520-39008 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      90520-39009 2.35 to 2.40 mm (0.0926 to 0.0944 in.)
      90520-39010 2.40 to 2.45 mm (0.0945 to 0.0964 in.)
      90520-39011 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      90520-39012 2.50 to 2.55 mm (0.0985 to 0.1003 in.)
    4. Using a snap ring expander, install a new transfer clutch hub shaft snap ring.
    5. Install the transfer high and low clutch sleeve.
      NOTE:

      Make sure that the transfer high and low clutch sleeve moves smoothly.

  6. INSTALL TRANSFER DRIVEN SPROCKET BEARING 
    1. Apply transfer oil to 2 new transfer driven sprocket bearings and the press-fit portion of the transfer driven sprocket.
    2. for Rear Side:

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

      GTY914950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-60012 
        1. 09316-00031
      NOTE:
      • Make sure the transfer driven sprocket bearing contacts the edge of the transfer driven sprocket, but do not press it in more than necessary.
      • Make sure that the transfer driven sprocket bearing moves smoothly.
    3. for Front Side:

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

      • SST: 09950-60011 
        1. 09951-00290
      • SST: 09950-70010 
        1. 09951-07100
      • SST: 09316-60012 
        1. 09316-00031
      • SST: 09527-10011 
      GTY920866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure the transfer driven sprocket bearing contacts the edge of the transfer driven sprocket, but do not press it in more than necessary.
      • Make sure that the transfer driven sprocket bearing moves smoothly.
  7. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY 
    1. Apply transfer oil to the O-ring of the transfer shift actuator assembly.
    2. Install the transfer shift actuator assembly with the 3 bolts.
      GTY709022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

      NOTE:

      Do not damage the O-ring.

    3. Using a screwdriver and hammer, install the transfer gear shift fork shaft snap ring.
      GTY568113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Install only the transfer gear shift fork shaft snap ring on the rear side of the transfer shift actuator shaft.

  8. INSTALL REAR TRANSFER OUTPUT SHAFT, TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVEN SPROCKET 
    NOTE:
    • w/ A.D.D.:

      Be careful not to drop the front drive clutch sleeve and No. 1 synchromesh shifting key.

    • w/o A.D.D.:

      Be careful not to drop the front drive clutch sleeve.

    • When using a vise, place aluminum plates between the part and vise.
    • When using a vise, do not overtighten it.
    1. Install the rear transfer output shaft, 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
      WARNING:

      Be careful not to burn yourself when the rear transfer case temperature is high.

      HINT: 

      When installation under normal temperatures is difficult, heat the rear transfer case to approximately 50 to 80 °C (122 to 176 °F), and then install it.

    2. Using a snap ring expander, install the transfer output shaft - shaft snap ring.
      GTY735849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      After installation, if there is any clearance along the inside diameter of the transfer output shaft snap ring, replace it with a new one.

    3. Using a screwdriver and hammer, install the transfer gear shift fork shaft snap ring.
      GTY568114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TRANSFER FRONT DRIVE SHIFT FORK SHAFT 
    1. Using a magnet hand, install the 2 shift interlock pin or rollers.
      GTY709015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. To install 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.
      GTY886382Courtesy 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
    3. Install the transfer front drive shift fork shaft.
    4. GTY708993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the transfer shift shaft stopper with the bolt.

      Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

    5. GTY568115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using a screwdriver and hammer, install the 2 transfer gear shift fork shaft snap rings.

    6. Clean the 2 shift detent ball spring plug holes.
      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
    7. Install the 2 shift detent balls and 2 shift detent ball compression springs.
    8. Type A:
      1. Using a 6 mm hexagon wrench, install 2 new shift detent ball spring plugs.

        Torque: 18.6 N.m (190 kgf/cm, 14 ft.lbf) 

    9. Type B:
      1. Install 2 new shift detent ball spring plugs.

        Torque: 26 N.m (265 kgf/cm, 19 ft.lbf) 

  10. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    1. Apply transfer oil to a new transfer low planetary gear bearing.
    2. Using SST and a press, install the transfer low planetary gear bearing as shown in the illustration.
      GTY926287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00470
        2. 09951-00570
        3. 09952-06010
      • SST: 09950-70010 
        1. 09951-07150

      Drive in depth (A)

      7.7 to 8.3 mm (0.3032 to 0.3267 in.)

  11. INSTALL TRANSFER INPUT SHAFT BEARING 
    1. Using SST and a press, install a new transfer input shaft bearing.
      • SST: 09223-15020 
      • SST: 09515-30010 
      • SST: 09950-70010 
        1. 09951-07100
      GTY840007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Rear Side
      NOTE:
      • Install the transfer input shaft bearing with the installation groove of the transfer low planetary gear bearing shaft snap ring facing the front side as shown in the illustration.
      • Make sure the transfer input shaft bearing contacts the edge of the transfer low planetary ring gear, but do not press it in more than necessary.
    2. Select a transfer input bearing shaft snap ring from the table below so that the clearance between the transfer input shaft bearing and transfer input bearing shaft snap ring is 0.1 mm (0.00393 in.) or less.
      GTY709063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Snap Ring Thickness

      Part No. Mark Specified Condition
      90520-72001 1 1.45 to 1.50 mm (0.0571 to 0.0590 in.)
      90520-72002 2 1.50 to 1.55 mm (0.0591 to 0.0610 in.)
      90520-72003 3 1.55 to 1.60 mm (0.0611 to 0.0629 in.)
      90520-72004 4 1.60 to 1.65 mm (0.0630 to 0.0649 in.)
      90520-72005 5 1.65 to 1.70 mm (0.0650 to 0.0669 in.)
    3. Using a snap ring expander, install a new transfer input bearing shaft snap ring.
  12. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    1. Apply transfer oil to the 2 No. 1 transfer input shaft seal rings.
    2. Install the 2 No. 1 transfer input shaft seal rings.
      GTY735857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When installing the No. 1 transfer input shaft seal ring, do not expand the inside diameter to 65.0 mm (2.55 in.) or more.

  13. INSTALL TRANSFER INPUT SHAFT 
    1. Apply transfer oil to the transfer low planetary gear bearing.
    2. Install the transfer low planetary gear bearing, No. 1 transfer thrust bearing race and transfer input shaft.
      TEXT IN ILLUSTRATION

      *1 Transfer Input Shaft
      *2 Transfer Low Planetary Gear Bearing
      *3 No. 1 Transfer Thrust Bearing Race
      GTY871496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When selecting a transfer low planetary gear bearing and No. 1 transfer thrust bearing race, select and install parts from the same manufacturer.

    3. Apply transfer oil to the manual transfer planetary carrier washer.
      GTY933006Courtesy 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
    4. Install the manual transfer planetary carrier washer.
    5. Install the transfer input gear stopper and transfer input gear stopper ball.
    6. Select a transfer input bearing shaft snap ring from the table below so that the thrust clearance of the transfer input gear stopper shaft snap ring is 0.05 to 0.15 mm (0.00197 to 0.00590 in.).
      GTY735847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Snap Ring Thickness

      Part No. Specified Condition
      90520-44003 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      90520-44004 2.15 to 2.20 mm (0.0847 to 0.0866 in.)
      90520-44005 2.20 to 2.25 mm (0.0867 to 0.0885 in.)
      90520-44006 2.25 to 2.30 mm (0.0886 to 0.0905 in.)
      90520-44007 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      90520-44008 2.35 to 2.40 mm (0.0926 to 0.0944 in.)
      90520-44009 2.40 to 2.45 mm (0.0945 to 0.0964 in.)
      90520-44010 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      90520-44011 2.50 to 2.55 mm (0.0985 to 0.100 in.)
      90520-44012 2.55 to 2.60 mm (0.101 to 0.102 in.)
      90520-44013 2.60 to 2.65 mm (0.103 to 0.104 in.)
      90520-44014 2.65 to 2.70 mm (0.105 to 0.106 in.)
      90520-44015 2.70 to 2.75 mm (0.107 to 0.108 in.)
      90520-44016 2.75 to 2.80 mm (0.109 to 0.110 in.)
      90520-44017 2.80 to 2.85 mm (0.111 to 0.112 in.)
      90520-44018 2.85 to 2.90 mm (0.113 to 0.114 in.)
      90520-44019 2.90 to 2.95 mm (0.115 to 0.116 in.)
      90520-44020 2.95 to 3.00 mm (0.117 to 0.118 in.)
      90520-44021 3.00 to 3.05 mm (0.119 to 0.120 in.)
    7. Using a snap ring expander, install a new transfer input gear stopper shaft snap ring.
      NOTE:

      After installation, if there is any clearance along the inside diameter of the transfer input gear stopper shaft snap ring, replace it with a new one.

  14. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Apply transfer oil to the transfer output shaft front needle roller bearing.
    2. Install the transfer output shaft front needle roller bearing.
      GTY709009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transfer low planetary gear spline piece.
      GTY709012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a screwdriver, install the transfer low planetary gear shaft snap ring.
      GTY920142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      The transfer low planetary gear shaft snap ring should be installed completely.

      HINT: 

      Tape the screwdriver tip before use.

      TEXT IN ILLUSTRATION

      *a Protective Tape
  15. INSTALL TRANSFER LOW PLANETARY RING GEAR 
    1. Install the transfer low planetary ring gear.
      GTY917479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Protective Tape
      Front Side
      NOTE:

      Install the transfer low planetary ring gear in the correct direction.

    2. Using a screwdriver, install the transfer low planetary ring gear hole snap ring.
      NOTE:

      The transfer low planetary gear shaft snap ring should be installed completely.

      HINT: 

      Tape the screwdriver tip before use.

  16. INSTALL TRANSFER CASE PLUG 
    1. Clean the transfer case plug hole.
      TEXT IN ILLUSTRATION

      *1 Transfer Case Plug
      *2 Transfer Case Compression Spring
      *3 Pin
    2. Install the pin and transfer case compression spring.
      GTY907910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new transfer case plug.

      Torque: 18.6 N.m (190 kgf/cm, 14 ft.lbf) 

  17. INSTALL TRANSFER LOW PLANETARY GEAR ASSEMBLY 
    1. Install the transfer low planetary gear assembly.
      GTY709008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      Be careful not to burn yourself when the front transfer case temperature is high.

      HINT: 

      When installation under normal temperatures is difficult, heat the front transfer case to approximately 50 to 80 °C (122 to 176 °F), and then install it.

    2. Using a snap ring expander, install the transfer low planetary gear bearing shaft snap ring.
      GTY709007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      After installation, if there is any clearance along the inside diameter of the transfer low planetary gear bearing shaft snap ring, replace it with a new one.

  18. INSTALL TRANSFER FRONT BEARING TYPE T OIL SEAL 
    1. Coat the lip of a new transfer front bearing type T oil seal with MP grease.
    2. Using SST and a hammer, install the transfer front bearing type T oil seal as shown in the illustration.
      • SST: 09950-60011 
        1. 09951-00410
        2. 09951-00570
        3. 09952-06010
      • SST: 09950-70010 
        1. 09951-07100

      Drive in depth (A)

      43.0 to 44.0 mm (1.70 to 1.73 in.)

      GTY938574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the transfer front bearing type T oil seal in the correct direction.
      • Be careful not to damage the transfer front bearing type T oil seal.
  19. INSTALL TRANSFER FRONT BEARING RETAINER SUB-ASSEMBLY 
    1. Clean the 5 bolt holes.
    2. Apply seal packing to the transfer front bearing retainer sub-assembly as shown in the illustration.
      GTY904107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Seal width (A)

      1.2 mm (0.0472 in.)

      NOTE:

      If the removed transfer front bearing retainer sub-assembly will be reused: After removing the transfer front bearing retainer sub-assembly, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the transfer front bearing retainer sub-assembly contact surface, 2) clean off any remaining old seal packing from the transfer front bearing retainer sub-assembly contact surface, and 3) reapply seal packing to the transfer front bearing retainer sub-assembly.

    3. Apply adhesive to 2 or 3 threads on the end of the 5 new bolts.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. Install the transfer front bearing retainer sub-assembly with the 5 bolts.

      Torque: 11.5 N.m (117 kgf/cm, 8 ft.lbf) 

      GTY708996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Tighten the bolts of the transfer front bearing retainer sub-assembly within 10 minutes of applying the seal packing.

        The seal packing will dry very quickly.

      • Be careful not to damage the transfer front bearing type T oil seal.
  20. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. GTY709004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Apply transfer oil to the transfer oil pump gear.

    2. Install the transfer oil pump gear.
    3. GTY568102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Apply transfer oil to a new transfer oil pump body O-ring.

    4. Install the transfer oil pump body O-ring.
      NOTE:
      • Do not scratch or twist the transfer oil pump body O-ring.
      • The transfer oil pump body O-ring should be installed completely.
    5. Install the transfer oil pump body sub-assembly with the 3 bolts.
      GTY709025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  21. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Install the transfer case magnet.
      GTY709021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transfer oil separator sub-assembly with the 3 bolts.

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

      NOTE:

      Be careful not to damage the transfer oil pump body O-ring.

  22. INSTALL REAR TRANSFER CASE 
    1. Apply transfer oil to the transfer output shaft front needle roller bearing, the inside diameter of the internal bush portion of the transfer input shaft and the fitting surfaces of the high and low clutch sleeve and transfer low planetary gear assembly.
    2. Apply seal packing to the rear transfer case as shown in the illustration.
      GTY864009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Seal width (A)

      1.2 mm (0.0472 in.)

      NOTE:

      If the removed rear transfer case will be reused: After removing the rear transfer case, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the rear transfer case contact surface, 2) clean off any remaining old seal packing from the rear transfer case contact surface, and 3) reapply seal packing to the rear transfer case.

    3. Install the rear transfer case and 4 brackets with the 12 bolts.
      TEXT IN ILLUSTRATION

      *1 Bracket

      Torque: 28 N.m (286 kgf/cm, 21 ft.lbf) 

      GTY932994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Tighten the bolts of the rear transfer case within 10 minutes of applying the seal packing.

      The seal packing will dry very quickly.

  23. INSTALL TRANSFER OUTPUT SHAFT WASHER 
    1. Install the No. 2 transfer output shaft spacer.
      GTY863895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Output Shaft Washer
      *2 No. 2 Transfer Output Shaft Spacer
    2. Install the 2 transfer output shaft washers.
  24. INSTALL TRANSFER EXTENSION HOUSING 
    1. Clean the 5 bolt holes.
    2. Apply seal packing to the transfer extension housing as shown in the illustration.
      GTY932553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Seal width (A)

      1.2 mm (0.0472 in.)

      NOTE:

      If the removed transfer extension housing will be reused: After removing the transfer extension housing, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the transfer extension housing contact surface, 2) clean off any remaining old seal packing from the transfer extension housing contact surface, and 3) reapply seal packing to the transfer extension housing.

    3. Apply adhesive to 2 or 3 threads on the end of the 5 new bolts.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. Install the transfer extension housing with the 5 bolts.

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

      GTY708987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Tighten the bolts of the transfer extension housing within 10 minutes of applying the seal packing.

      The seal packing will dry very quickly.

  25. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 

    See step  5

  26. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Rear Side) 
    1. Apply transfer oil to a new transfer output shaft O-ring and the fitting portions of the output shaft companion flange sub-assembly and rear transfer output shaft.
    2. Using SST to hold the output shaft companion flange sub-assembly, install the transfer output shaft O-ring and a new transfer output shaft companion flange nut.
      GTY911959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09330-00021 
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold

      Torque: 127.4 N.m (1299 kgf/cm, 94 ft.lbf) 

      NOTE:
      • Do not scratch or twist the transfer output shaft O-ring.
      • The transfer output shaft O-ring should be installed completely.
    3. Using a chisel and hammer, stake the transfer output shaft companion flange nut as shown in the illustration.
      GTY944611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Output Shaft Companion Flange Nut
      *2 Rear Transfer Output Shaft
      *a Correct
      *b Incorrect
  27. INSTALL TRANSFER CASE OIL SEAL 

    See step  8

  28. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Front Side) 
    1. Using SST and hammer, install a new transfer output shaft companion flange oil seal.
      GTY872172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00220
        2. 09951-00310
        3. 09952-06010
      • SST: 09950-70010 
        1. 09951-07100

      Drive in depth (A)

      38.0 to 39.0 mm (1.50 to 1.53 in.)

      NOTE:

      Install the transfer output shaft companion flange oil seal in the correct direction.

    2. Apply transfer oil to the fitting portions of the output shaft companion flange sub-assembly and transfer driven sprocket.
    3. Using SST to hold the output shaft companion flange sub-assembly, install a new transfer output shaft companion flange nut.
      • SST: 09330-00021 
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
      GTY908869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 118 N.m (1203 kgf/cm, 87 ft.lbf) 

    4. Using a chisel and hammer, stake the transfer output shaft companion flange nut as shown in the illustration.
      GTY921719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Output Shaft Companion Flange Nut
      *2 Rear Transfer Output Shaft
      *a Correct
      *b Incorrect
  29. INSTALL NO. 1 TRANSFER CASE PLUG 
    1. GTY932314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install a new No. 1 transfer case gasket to the No. 1 transfer case plug (filler plug), and then install the No. 1 transfer case plug (filler plug).

      Torque: 37 N.m (377 kgf/cm, 27 ft.lbf) 

      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. Install a new transfer drain plug gasket to the transfer drain plug, and then install the transfer drain plug.

      Torque: 37 N.m (377 kgf/cm, 27 ft.lbf) 

  30. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Install the breather oil deflector.
      GTY708995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY708997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the transfer case cover sub-assembly with the 4 bolts.

      Torque: 18 N.m (184 kgf/cm, 13 ft.lbf) 

  31. INSTALL ACTUATOR BREATHER HOSE 
    1. Install the 2 clamps and actuator breather hose as shown in the illustration.
      GTY870949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a 0 to 3.0 mm
      NOTE:
      • Install the actuator breather hose so that it passes between the rear transfer case and transfer shift actuator assembly.
      • Fully install the actuator breather hose to the base of the transfer shift actuator assembly.
      • Install the actuator breather hose so that the net protector in area A extends 0 to 3.0 mm (0 to 0.118 in.) from the clamp.
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