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Home >> Toyota >> 2016 >> 4Runner Limited, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Transfer Case (VF2BM) - Service Information) >> Transfer Assembly >> Disassembly [08/2015 - 08/2019] >> Procedure

Disassembly [08/2015 - 08/2019]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY 
    GTY702224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 4 bolts and the transfer case cover sub-assembly.
  2. REMOVE BREATHER OIL DEFLECTOR SUB-ASSEMBLY 
    1. Remove the breather oil deflector sub-assembly.
  3. REMOVE FRONT TRANSFER BEARING RETAINER SUB-ASSEMBLY 
    GTY692007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 5 bolts and the front transfer bearing retainer sub-assembly.

      HINT: 

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

  4. REMOVE FRONT TRANSFER BEARING RETAINER OIL SEAL 
    1. Using a screwdriver and hammer, remove the front transfer bearing retainer oil seal.
  5. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    GTY694458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a chisel and hammer, loosen the staked part of the lock nut.
    2. Using SST to hold the front output shaft companion flange sub-assembly, remove the lock nut.
      • SST: 09330-00021 
    3. Using SST, remove the front output shaft companion flange sub-assembly.
      GTY717309Courtesy 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
  6. REMOVE FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using a screwdriver and hammer, remove the front transfer output shaft companion flange oil seal.
      NOTE:

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

  7. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Remove the rear output shaft companion flange sub-assembly using the same procedure as for the front output shaft companion flange sub-assembly.
      • SST: 09330-00021 
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04051
        6. 09957-04010
        7. 09958-04011
  8. REMOVE REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Using a screwdriver and hammer, remove the rear transfer output shaft companion flange oil seal.
  9. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Remove the bolt and speedometer driven hole cover sub-assembly.
    2. Remove the O-ring from speedometer driven hole cover sub-assembly.
  10. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    GTY692008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 5 bolts and transfer extension housing sub-assembly.

      HINT: 

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

  11. REMOVE TRANSFER CASE REAR OIL SEAL 
    1. Using a screwdriver and hammer, remove the transfer case rear oil seal.
  12. REMOVE TRANSFER OUTPUT SHAFT WASHER 
    1. Remove the 2 transfer output shaft washers.
      GTY725562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Collar
      *2 Transfer Output Shaft Washer
  13. REMOVE COLLAR 
    1. Remove the collar.
  14. REMOVE REAR TRANSFER CASE 
    GTY725377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  15. REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT 
    GTY728866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a hexagon wrench (6 mm), remove the 2 shift detent ball spring plugs, 2 shift fork compression springs and 2 shift detent balls.
      TEXT IN ILLUSTRATION

      *1 Shift Detent Ball
      *2 Shift Fork Compression Spring
      *3 Shift Detent Ball Spring Plug
    2. Using 2 screwdrivers and a hammer, tap out the 2 transfer gear shift fork shaft snap rings.
      GTY206004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and transfer shift shaft stopper.
      GTY728860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. To pull out the transfer front drive shift fork shaft, shift the No. 1 and No. 2 transfer gear shift forks to the positions shown in the illustration.
      GTY710132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 2 Transfer Gear Shift Fork
      *2 No. 1 Transfer Gear Shift Fork
      *3 Transfer Front Drive Shift Fork Shaft
      *4 Shift Fork Shaft Snap Ring
    5. Pull out the transfer front drive shift fork shaft.
    6. Using a magnetic finger, remove the 2 shift inter lock pins.
      GTY728859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE REAR OUTPUT SHAFT ASSEMBLY, FRONT DRIVE CHAIN, DRIVEN SPROCKET ASSEMBLY, NO. 1 AND NO. 2 TRANSFER GEAR SHIFT FORKS 
    GTY173642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using 2 screwdrivers and a hammer, tap out the transfer gear shift fork shaft snap ring.

      HINT: 

      Remove only the transfer gear shift fork shaft snap ring on the front side of the transfer front drive shift fork shaft.

    2. Using a snap ring expander, remove the transfer output shaft snap ring.
      GTY740236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mount the rear transfer case in a vise.
      GTY740704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a plastic-faced hammer, carefully tap the rear transfer case and remove the rear output shaft assembly, driven sprocket assembly, front drive chain, No. 1 and No. 2 transfer gear shift forks.
    5. Remove the driven sprocket assembly, front drive chain, No. 1 and No. 2 transfer gear shift forks from the rear output shaft assembly.
  17. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY 
    GTY206009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using 2 screwdrivers and a hammer, remove the transfer gear shift fork shaft snap ring.
    2. Remove the 3 bolts and transfer shift actuator assembly.
  18. REMOVE NO. 1 TRANSFER INDICATOR SWITCH 
    GTY705879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the O-ring, the 2 No. 1 transfer indicator switches and 2 gaskets.
      TEXT IN ILLUSTRATION

      *1 No. 1 transfer indicator switch (L4 Position)
      *2 No. 1 transfer indicator switch (4WD Position)
  19. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    GTY277158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, remove the transfer driven sprocket bearing.
      • SST: 09555-55010 
  20. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING 
    GTY365752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, a press and steel bar, remove the transfer input gear radial ball bearing.
      • SST: 09555-55010 
      TEXT IN ILLUSTRATION

      *1 Steel Bar
  21. REMOVE FILLER PLUG 
    1. Remove the filler plug and gasket.
  22. REMOVE DRAIN PLUG 
    1. Remove the drain plug and gasket.
  23. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    GTY728855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 bolts and transfer oil separator sub-assembly.
  24. REMOVE TRANSFER CASE MAGNET 
    1. Remove the transfer case magnet.
  25. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    GTY692009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 bolts and transfer oil pump body sub-assembly.
  26. REMOVE TRANSFER OIL PUMP GEAR 
    1. Remove the transfer oil pump gear.
  27. REMOVE TRANSFER OIL PUMP BODY O-RING 
    GTY154636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the transfer oil pump body O-ring.
  28. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY 
    GTY728854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, remove the transfer low planetary gear bearing shaft snap ring.
    2. Remove the low planetary gear assembly w/ input shaft assembly.
      GTY156442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE TRANSFER CASE PLUG 
    GTY694448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the transfer case plug.
    2. Using a magnetic finger, remove the transfer case compression spring and pin.
      TEXT IN ILLUSTRATION

      *1 Transfer Case Plug
      *2 Transfer Case Compression Spring
      *3 Pin
  30. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    GTY740707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the transfer low planetary ring gear hole snap ring.
    2. Remove the transfer low planetary ring gear from the front case.
  31. REMOVE TRANSFER CASE FRONT OIL SEAL 
    1. Using a screwdriver and hammer, remove the transfer case front oil seal.
  32. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    GTY702574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the transfer low planetary gear shaft snap ring.
    2. Remove the transfer low planetary gear spline piece.
      GTY702575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
    GTY740689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 transfer output shaft front needle roller bearings.
  34. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    GTY136731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, remove the transfer input gear stopper shaft snap ring.
  35. REMOVE TRANSFER INPUT GEAR STOPPER 
    GTY689428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the transfer input gear stopper.
      TEXT IN ILLUSTRATION

      *1 Manual Transfer Planetary Carrier Washer
      *2 Transfer Input Gear Stopper Ball
      *3 Transfer Input Gear Stopper
  36. REMOVE TRANSFER INPUT GEAR STOPPER BALL 
    1. Remove the transfer input gear stopper ball.
  37. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER 
    1. Remove the manual transfer planetary carrier washer.
  38. REMOVE TRANSFER INPUT SHAFT 
    GTY700297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the transfer input shaft.
      TEXT IN ILLUSTRATION

      *1 Transfer Low Planetary Gear Bearing
      *2 No. 1 Transfer Thrust Bearing Race
      *3 Transfer Input Shaft
  39. REMOVE NO. 1 TRANSFER THRUST BEARING RACE 
    1. Remove the No. 1 transfer thrust bearing race.
  40. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    1. Remove the transfer low planetary gear bearing.
  41. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    GTY378984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 No. 1 transfer input shaft seal rings.
      TEXT IN ILLUSTRATION

      *1 No. 1 Transfer Input Shaft Seal Ring
  42. REMOVE TRANSFER INPUT SHAFT BEARING 
    GTY722460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, remove the transfer input bearing shaft snap ring.
    2. Using SST and a press, remove the transfer input shaft bearing.
      • SST: 09554-30011 
      • SST: 09555-55010 
  43. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    GTY722756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the transfer low planetary gear bearing.
      • SST: 09612-65014 
        1. 09612-01030
        2. 09612-01050
      NOTE:

      Hang SST securely to the clearance between the bearing and the low planetary gear.

  44. INSPECT DRIVE SPROCKET THRUST CLEARANCE 
    GTY740690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a feeler gauge, measure the transfer drive sprocket sub-assembly thrust clearance.

      Standard clearance

      0.10 to 0.25 mm (0.00394 to 0.00984 in.)

      Maximum clearance

      0.25 mm (0.00984 in.)

      If the clearance exceeds the maximum, replace the transfer drive sprocket sub-assembly.

  45. REMOVE TRANSFER CLUTCH HUB 
    GTY206019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, remove the transfer clutch hub shaft snap ring.
    2. Remove the transfer high and low clutch sleeve.
    3. Using a press, remove the transfer clutch hub.
      GTY210678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING 
    GTY693696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, remove the rear transfer output shaft radial ball bearing.
      • SST: 09555-55010 
  47. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
    GTY722861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the transfer output shaft spacer and transfer output shaft spacer ball.
    2. Remove the transfer drive sprocket sub-assembly, transfer synchronizer inner ring, center ring, outer ring and front drive clutch sleeve together.
    3. Remove the transfer drive sprocket bearing.
    4. Remove the synchronizer inner ring, center ring, outer ring and front drive clutch sleeve.
    5. Remove the 3 No. 1 transfer synchromesh shifting keys and the 2 No. 1 transfer synchromesh shifting key springs.
      TEXT IN ILLUSTRATION

      *1 Transfer Output Shaft Spacer
      *2 Transfer Output Shaft Spacer Ball
      *3 Transfer Drive Sprocket Sub-assembly
      *4 Transfer Synchronizer Inner Ring
      *5 Transfer Synchronizer Center Ring
      *6 Transfer Synchronizer Outer Ring
      *7 Front Drive Clutch Sleeve
      *8 Transfer Drive Sprocket Bearing
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