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Home >> Toyota >> 2016 >> 4Runner Limited, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Transfer Case (VF2A) - Service Information) >> Transfer Assembly >> Disassembly [08/2015 - ] >> Procedure

Disassembly [08/2015 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE TRANSFER INDICATOR SWITCH (4WD POSITION) 

    See step  2

  2. REMOVE TRANSFER INDICATOR SWITCH (L4 POSITION) 

    See step  3

  3. REMOVE TRANSFER INDICATOR SWITCH (NEUTRAL POSITION) 

    See step  4

  4. REMOVE TRANSFER CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY 
    1. Remove the 4 bolts and retainer.
  5. REMOVE BREATHER OIL DEFLECTOR 
    1. Remove the breather oil deflector.
  6. REMOVE TRANSFER BEARING RETAINER SUB-ASSEMBLY 
    1. Remove the 5 bolts and bearing retainer.

      HINT: 

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

  7. REMOVE TRANSFER BEARING RETAINER OIL SEAL 
    1. Using a screwdriver and hammer, tap off the oil seal from the bearing retainer.
      NOTE:

      Be careful not to damage the oil seal and bearing retainer contact surfaces.

  8. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using a chisel and hammer, loosen the staked part of the lock nut.
    2. Using SST to hold the companion flange, remove the lock nut.
      • SST: 09330-00021 
      GTY732570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the companion flange.
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04051
        6. 09957-04010
        7. 09958-04011
      GTY282659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.
      NOTE:

      Be careful not to damage the oil seal and companion flange contact surfaces.

  10. REMOVE TRANSFER CASE FRONT OIL SEAL 

    See step  5

  11. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using a chisel and hammer, loosen the staked part of the lock nut.
    2. Using SST to hold the companion flange, remove the lock nut.
      GTY233471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09330-00021 
    3. Using SST, remove the companion flange.
      GTY216364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04051
        6. 09957-04010
        7. 09958-04011
  12. REMOVE REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.
      NOTE:

      Be careful not to damage the oil seal and companion flange contact surfaces.

  13. REMOVE TRANSFER CASE REAR OIL SEAL 

    See step  5

  14. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Remove the bolt and speedometer driven hole cover sub-assembly.
    2. Remove the O-ring from the hole cover.
  15. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 5 bolts and extension housing.

      HINT: 

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

  16. REMOVE TRANSFER OUTPUT SHAFT WASHER 
    1. Remove the 2 output shaft washers.
  17. REMOVE TRANSFER SPEEDOMETER DRIVE GEAR 
    1. Remove the speedometer drive gear and ball.
  18. REMOVE REAR TRANSFER CASE 
    1. Remove the 12 bolts and clamp.
    2. Remove the rear transfer case.

      HINT: 

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

  19. REMOVE FRONT TRANSFER DRIVE SHIFT FORK SHAFT 
    1. Using a hexagon wrench, remove the 2 plugs.
    2. Using a magnet hand, remove the 2 springs and 2 balls from both holes.
    3. Mount the rear transfer case in a vise.
      NOTE:

      Place aluminum plates on the vise to prevent damage to the rear transfer case.

    4. Using a 5 mm pin punch and hammer, tap off the 2 slotted pins from the shift shaft stopper and No. 2 transfer gear shift fork.
      GTY200982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Hold the shift fork shaft in place by hand when removing the pin punch.
      GTY200983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the shift fork shaft, No. 1 gear shift fork, spring and shift shaft stopper.
    7. Using a magnet hand, remove the straight pin.
  20. REMOVE TRANSFER HIGH AND LOW SHIFT FORK SHAFT 
    1. Remove the shift fork shaft and No. 2 gear shift fork.
  21. REMOVE REAR TRANSFER OUTPUT SHAFT, FRONT TRANSFER DRIVE CHAIN AND TRANSFER DRIVEN SPROCKET 
    GTY693709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, remove the snap ring.
    2. Using a plastic-faced hammer, carefully tap the rear transfer case and remove the output shaft together with the drive chain and driven sprocket.
      GTY700922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Aluminum Plate
    3. Remove the output shaft and driven sprocket from the drive chain.
  22. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    GTY277158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, press out the bearing.
      • SST: 09555-55010 
      NOTE:

      Be careful not to drop or damage the driven sprocket.

  23. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING 
    GTY270536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, a press and steel bar, press out the bearing.
      • SST: 09555-55010 
      NOTE:

      Be careful not to drop or damage the driven sprocket.

  24. REMOVE FILLER PLUG 
    1. Remove the filler plug and gasket.
  25. REMOVE DRAIN PLUG 
    1. Remove the drain plug and gasket.
  26. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    GTY289796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 bolts and oil separator.
  27. REMOVE TRANSFER CASE MAGNET 
  28. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Remove the 3 bolts and oil pump body.
  29. REMOVE TRANSFER OIL PUMP BODY O-RING 
    GTY154636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the O-ring from the oil pump body.
      NOTE:

      Be careful not to damage the oil pump body.

  30. REMOVE TRANSFER OIL PUMP GEAR 
    1. Remove the oil pump gear.
  31. REMOVE TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT 
    GTY676821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, remove the snap ring.
    2. Remove the low planetary gear together with the input shaft.
  32. REMOVE TRANSFER CASE PLUG 
    1. Remove the case plug.
  33. REMOVE COMPRESSION SPRING 
    1. Remove the spring.
  34. REMOVE PIN 
    1. Remove the pin.
  35. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    GTY632116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, pry out the snap ring.
      NOTE:

      Be careful not to damage the front transfer case.

    2. Remove the ring gear from the front transfer case.
  36. REMOVE TRANSFER CASE OIL SEAL 
    1. Using a screwdriver and hammer, tap out the 2 oil seals.
      NOTE:

      Be careful not to damage the oil seal and front transfer case contact surfaces.

  37. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    GTY740668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, pry out the snap ring.
      NOTE:

      Be careful not to damage the low planetary gear.

    2. Remove the spline piece.
  38. REMOVE FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING 
    1. Remove the needle roller bearing.
  39. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    GTY182236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, remove the snap ring.
  40. REMOVE TRANSFER INPUT GEAR STOPPER 
    1. Remove the input gear stopper.
  41. REMOVE TRANSFER INPUT GEAR STOPPER BALL 
    1. Remove the ball.
  42. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER 
    1. Remove the washer.
  43. REMOVE TRANSFER INPUT SHAFT 
    1. Remove the input shaft.
  44. REMOVE NO. 1 TRANSFER THRUST BEARING RACE 
    1. Remove the bearing race.
  45. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    1. Remove the bearing.
  46. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    1. Remove the 2 seal rings.
  47. REMOVE TRANSFER INPUT SHAFT BEARING 
    1. Using a snap ring expander, remove the snap ring.
    2. Using SST and a press, press out the bearing.
      • SST: 09555-55010 
      • SST: 09950-70010 
        1. 09951-07150
      • SST: 09950-60020 
        1. 09951-00750
      NOTE:

      Be careful not to drop or damage the low planetary gear.

      GTY696583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    GTY247634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the bearing.
      • SST: 09612-65014 
        1. 09612-01030
        2. 09612-01050
      NOTE:

      Hang SST securely between the bearing and low planetary gear.

  49. REMOVE TRANSFER CLUTCH HUB 
    1. Using a snap ring expander, remove the snap ring.
    2. Remove the high and low clutch sleeves.
    3. Using a press, press out the clutch hub.
      GTY235751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to drop or damage the clutch hub.

  50. REMOVE REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING 
    1. Using SST and a press, press out the bearing.
      GTY211581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09555-55010 
      NOTE:

      Be careful not to drop or damage the output shaft.

  51. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
    1. Remove the spacer and ball.
    2. Remove the drive sprocket with front drive clutch sleeve.
    3. Remove the needle roller bearing.
    4. Remove the front drive synchronizer ring.
    5. Remove the front drive sleeve, 3 shifting keys and 2 shifting key springs from the drive sprocket.
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