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

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL FRONT DRIVE CLUTCH SLEEVE 
    GTY179672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the front drive clutch sleeve onto the rear transfer output shaft.
      NOTE:

      Make sure that the front drive clutch sleeve is installed facing in the correct direction.

    2. Install the 3 No. 1 synchromesh shifting keys and the 2 No. 1 synchromesh shifting keys spring.
      GTY723207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Synchromesh Shifting Key
      NOTE:

      Install the No. 1 synchromesh shifting key springs so that their end gaps are not in line.

  2. INSTALL TRANSFER SYNCHRONIZER RING SET 
    GTY717547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the transfer synchronizer outer ring onto the rear transfer output shaft.
      NOTE:

      Align the slots of the transfer synchronizer outer ring with the shifting keys.

    2. Install the transfer synchronizer center ring and the transfer synchronizer inner ring onto the rear transfer output shaft.
      NOTE:

      Align the slots of the transfer synchronizer outer ring with those of the transfer synchronizer inner ring.

      TEXT IN ILLUSTRATION

      *1 Transfer Synchronizer Outer Ring
      *2 Transfer Synchronizer Center Ring
      *3 Transfer Synchronizer Inner Ring
  3. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
    GTY722906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new transfer drive sprocket bearing.
    2. Install the transfer drive sprocket sub-assembly.
      NOTE:

      Align the holes in the transfer drive sprocket sub-assembly with the protrusions on the synchronizer center ring.

    3. Install the transfer output shaft spacer so that it is aligned it with the transfer output shaft spacer ball.
      TEXT IN ILLUSTRATION

      *1 Transfer Drive Sprocket Bearing
      *2 Transfer Drive Sprocket Sub-assembly
      *3 Transfer Output Shaft Spacer
      *4 Transfer Output Shaft Spacer Ball
  4. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING 
    GTY717126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, install a new rear transfer output shaft radial ball bearing with the output shaft snap ring groove facing toward the rear.
      • SST: 09316-60011 
        1. 09316-00011
        2. 09316-00071
      TEXT IN ILLUSTRATION

      *1 Transfer Output Shaft Rear Radial Ball Bearing
  5. INSPECT DRIVE SPROCKET THRUST CLEARANCE 
    GTY740690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a feeler gauge, measure the drive sprocket 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 drive sprocket sub-assembly.

  6. INSTALL TRANSFER HIGH AND LOW CLUTCH SLEEVE 
    GTY714876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the transfer high and low clutch sleeve onto the transfer clutch hub.
      TEXT IN ILLUSTRATION

      *1 Transfer High and Low Clutch Sleeve
      *2 Transfer Clutch Hub
      Front
      NOTE:

      Make sure that the high and low clutch hub is installed facing in the correct direction.

  7. INSTALL TRANSFER CLUTCH HUB 
    GTY210679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a press, install the transfer clutch hub.
    2. Select a transfer clutch hub shaft snap ring that allows the minimum axial play.
      GTY174403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Part No. Thickness mm (in.)
      90520-39013 2.10 to 2.15 (0.0827 to 0.0846)
      90520-39014 2.15 to 2.20 (0.0846 to 0.0866)
      90520-39004 2.20 to 2.25 (0.0866 to 0.0886)
      90520-39005 2.25 to 2.30 (0.0886 to 0.0906)
      90520-39006 2.30 to 2.35 (0.0906 to 0.0925)
      90520-39007 2.35 to 2.40 (0.0925 to 0.0945)
      90520-39008 2.40 to 2.45 (0.0945 to 0.0965)
      90520-39009 2.45 to 2.50 (0.0965 to 0.0984)
      90520-39010 2.50 to 2.55 (0.0984 to 0.1004)
      90520-39011 2.00 to 2.05 (0.0787 to 0.0807)
      90520-39012 2.05 to 2.10 (0.0807 to 0.0827)
    3. Using a snap ring expander, install the new transfer clutch hub shaft snap ring.
  8. INSTALL TRANSFER LOW PLANETARY RING GEAR 
    GTY692010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the transfer low planetary ring gear onto the front transfer case.
      TEXT IN ILLUSTRATION

      Front
      NOTE:

      Be sure to install the transfer low planetary ring gear facing in the correct direction.

    2. Using a screwdriver, install the transfer low planetary ring gear hole snap ring.
      GTY740707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TRANSFER CASE PLUG 
    GTY694448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the pin and transfer case compression spring.
    2. Apply adhesive to the transfer case plug threads.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the transfer case plug.

      Torque: 19 N.m (190 kgf/cm, 14 ft.lbf) 

      TEXT IN ILLUSTRATION

      *1 Transfer Case Plug
      *2 Transfer Case Compression Spring
      *3 Pin
  10. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    GTY687813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, tap in a new transfer low planetary gear bearing.
      • SST: 09950-60010 
        1. 09951-00570
      • SST: 09950-70010 
        1. 09951-07100

      Press in depth

      7.7 to 8.3 mm (0.303 to 0.327 in.)

  11. INSTALL TRANSFER INPUT SHAFT BEARING 
    GTY697530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, install a new transfer input shaft bearing with the groove facing forward.
      • SST: 09223-15020 
      • SST: 09515-30010 
      • SST: 09950-70010 
        1. 09951-07100
    2. Select a transfer input bearing shaft snap ring that allows 0.1 mm (0.004 in.) or less axial play.
      GTY210675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Mark Thickness mm (in.)
      1 1.45 to 1.50 (0.0571 to 0.0591)
      2 1.50 to 1.55 (0.0591 to 0.0610)
      3 1.55 to 1.60 (0.0610 to 0.0630)
      4 1.60 to 1.65 (0.0630 to 0.0650)
      5 1.65 to 1.70 (0.0650 to 0.0669)
    3. Using a snap ring expander, install the new transfer input bearing shaft snap ring.
  12. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    GTY380838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 to the transfer input shaft.
      NOTE:

      When installing the No. 1 transfer input shaft seal ring, make sure that its inner diameter does not exceed 65 mm (2.55 in.).

      TEXT IN ILLUSTRATION

      *1 No. 1 Transfer Input Shaft Seal Ring
  13. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    1. Install the transfer low planetary gear bearing to the transfer low planetary gear assembly.
      GTY700297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be sure to install the transfer low planetary gear bearing so that it is facing in the correct direction.
      • When the transfer low planetary gear bearing is replaced with a new one, be sure to replace the No. 1 transfer thrust bearing race at the same time.
      TEXT IN ILLUSTRATION

      *1 Transfer Low Planetary Gear Assembly
      *2 Transfer Low Planetary Gear Bearing
      *3 No. 1 Transfer Thrust Bearing Race
      *4 Transfer Input Shaft
  14. INSTALL NO. 1 TRANSFER THRUST BEARING RACE 
    1. Install the No. 1 transfer thrust bearing race to the transfer low planetary gear assembly.
      NOTE:

      When the No. 1 transfer thrust bearing race is replaced with a new one, be sure to replace the transfer low planetary gear bearing at the same time.

  15. INSTALL TRANSFER INPUT SHAFT 
    1. Apply transfer oil to the contact surfaces of the transfer input shaft and transfer low planetary gear.
    2. Install the transfer input shaft to the transfer low planetary gear assembly.
  16. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER 
    GTY689428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Apply transfer oil to the manual transfer planetary washer.
    2. Install the washer to the transfer low planetary gear assembly.
      TEXT IN ILLUSTRATION

      *1 Manual Transfer Planetary Carrier Washer
      *2 Transfer Input Gear Stopper Ball
      *3 Transfer Input Gear Stopper
  17. INSTALL TRANSFER INPUT GEAR STOPPER BALL 
    1. Install the transfer input gear stopper ball to the transfer input shaft.
  18. INSTALL TRANSFER INPUT GEAR STOPPER 
    1. Install the transfer input gear stopper to the transfer low planetary gear assembly.
  19. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    GTY154654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Select a transfer input gear stopper shaft snap ring that allows 0.1 to 0.2 mm (0.00394 to 0.00787 in.) axial play.
      Part No. Thickness mm (in.)
      90520-44003 2.10 to 2.15 (0.0827 to 0.0846)
      90520-44004 2.15 to 2.20 (0.0846 to 0.0866)
      90520-44005 2.20 to 2.25 (0.0866 to 0.0886)
      90520-44006 2.25 to 2.30 (0.0886 to 0.0906)
      90520-44007 2.30 to 2.35 (0.0906 to 0.0925)
      90520-44008 2.35 to 2.40 (0.0925 to 0.0945)
      90520-44009 2.40 to 2.45 (0.0945 to 0.0965)
      90520-44010 2.45 to 2.50 (0.0965 to 0.0984)
      90520-44011 2.50 to 2.55 (0.0984 to 0.1004)
      90520-44012 2.55 to 2.60 (0.1004 to 0.1204)
      90520-44013 2.60 to 2.65 (0.1024 to 0.1043)
      90520-44014 2.65 to 2.70 (0.1043 to 0.1063)
      90520-44015 2.70 to 2.75 (0.1063 to 0.1083)
      90520-44016 2.75 to 2.80 (0.1083 to 0.1102)
      90520-44017 2.80 to 2.85 (0.1102 to 0.1122)
      90520-44018 2.85 to 2.90 (0.1122 to 0.1142)
      90520-44019 2.90 to 2.95 (0.1142 to 0.1161)
      90520-44020 2.95 to 3.00 (0.1161 to 0.1181)
      90520-44021 3.00 to 3.05 (0.1181 to 0.1201)
    2. Using a snap ring expander, install the new transfer input gear stopper shaft snap ring.
      GTY136731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL TRANSFER CASE FRONT OIL SEAL 

    See step  6

  21. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING 
    GTY740689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 2 transfer output shaft front needle roller bearings.
  22. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    GTY702575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the transfer low planetary gear spline piece.
    2. Using a screwdriver, install the transfer low planetary ring gear shaft snap ring.
      GTY702574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the end gap of the transfer low planetary ring gear shaft snap ring is not aligned with the cutout of the planetary carrier.

  23. INSTALL TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY 
    GTY156442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the transfer low planetary gear assembly w/ transfer input shaft.

      HINT: 

      If necessary, heat the front case to about 50 to 80°C (122 to 176°F).

    2. Using a snap ring expander, install the transfer low planetary gear bearing shaft snap ring.
      GTY728854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL TRANSFER OIL PUMP GEAR 
    1. Install the transfer oil pump gear.
  25. INSTALL TRANSFER OIL PUMP BODY O-RING 
    GTY671089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with transfer oil and install it onto the transfer oil pump body sub-assembly.
  26. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    GTY692009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the transfer oil pump body sub-assembly with the 3 bolts.

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

  27. INSTALL TRANSFER CASE MAGNET 
    1. Install the transfer case magnet.
  28. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    GTY728855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the transfer oil separator sub-assembly with the 3 bolts.

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

  29. INSTALL FILLER PLUG 
    1. Install the filler plug and a new gasket.

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

  30. INSTALL DRAIN PLUG 
    1. Install the drain plug and a new gasket.

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

  31. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING 
    GTY718899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, install a new transfer input gear radial ball bearing.
      • SST: 09316-60011 
        1. 09316-00031
  32. INSTALL TRANSFER DRIVEN SPROCKET BEARING 
    GTY154671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a press, install a new transfer driven sprocket bearing.
  33. INSTALL NO. 1 TRANSFER INDICATOR SWITCH 
    GTY705879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with transfer oil and install it onto the transfer shift actuator assembly.
    2. Install 2 new gaskets and the 2 No. 1 transfer indicator switches onto the transfer shift actuator assembly.

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

      TEXT IN ILLUSTRATION

      *1 No. 1 transfer indicator switch (L4 Position)
      *2 No. 1 transfer indicator switch (4WD Position)
  34. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY 
    GTY206013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the transfer shift actuator assembly with the 3 bolts.

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

    2. Using a screwdriver and hammer, tap in the transfer gear shift fork shaft snap ring.

      HINT: 

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

  35. INSTALL REAR OUTPUT SHAFT ASSEMBLY, FRONT DRIVE CHAIN, DRIVEN SPROCKET ASSEMBLY, NO. 1 AND NO. 2 TRANSFER GEAR SHIFT FORKS 
    GTY691433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the driven sprocket assembly, front drive chain and No. 1 and No. 2 transfer gear shift forks onto the rear output shaft assembly.
      NOTE:

      Make sure that the No. 1 and No. 2 transfer gear shift forks are installed facing in the correct direction.

      TEXT IN ILLUSTRATION

      *1 No. 2 Transfer Gear Shift Fork
      *2 No. 1 Transfer Gear Shift Fork
      Front
    2. Fix the rear transfer case in a vise.
      GTY740704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the rear output shaft assembly, front drive chain, driven sprocket assembly, No. 1 and No. 2 transfer gear shift forks onto the rear transfer case.
      NOTE:

      Do not let the front drive clutch sleeve or No. 1 transfer synchromesh shifting key drop.

      HINT: 

      If necessary, heat the rear case to about 50 to 80°C (122 to 176°F).

    4. Using a snap ring expander, install the transfer output shaft snap ring.
      GTY740236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a screwdriver and hammer, tap in the transfer gear shift fork shaft snap ring.
      GTY206015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Check that the rear output shaft assembly and driven sprocket assembly turn smoothly.

  36. INSTALL TRANSFER FRONT DRIVE SHIFT FORK SHAFT 
    GTY728859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a magnetic finger, install the 2 shift inter lock pins onto the No. 1 and No. 2 transfer gear shift forks.
    2. To push in 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.
      GTY723609Courtesy 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 Transfer Gear Shift Fork Shaft Snap Ring
    3. Push in the transfer front drive shift fork shaft.
      NOTE:

      Make sure that the transfer front drive shift fork shaft is installed facing in the correct direction.

    4. Install the transfer shift shaft stopper with the bolt.
      GTY728860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    5. Using a screwdriver and hammer, tap the 2 transfer gear shift fork shaft snap rings into the transfer front drive shift fork shaft.
      GTY206016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 2 shift detent balls and 2 shift fork compression springs onto the No. 1 and No. 2 transfer gear shift forks.
      GTY728866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Shift Detent Ball
      *2 Shift Fork Compression Spring
      *3 Shift Detent ball Spring Plug
    7. Apply adhesive to the shift detent ball spring plug threads.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    8. Using a hexagon wrench (6 mm), install the 2 shift detent ball spring plugs onto the No. 1 and No. 2 transfer gear shift forks.

      Torque: 19 N.m (190 kgf/cm, 14 ft.lbf) 

  37. INSTALL REAR TRANSFER CASE 
    GTY735446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Apply seal packing to the rear transfer case, as shown in the illustration.
      TEXT IN ILLUSTRATION

      *1 Seal Packing

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    2. Engage the clamp and install the rear transfer case with the 12 bolts.
      GTY725377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  38. INSTALL COLLAR 
    1. Install the collar.
      GTY725562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Collar
      *2 Transfer Output Shaft Washer
  39. INSTALL TRANSFER OUTPUT SHAFT WASHER 
    1. Install the 2 transfer output shaft washers.
  40. INSTALL TRANSFER CASE REAR OIL SEAL 

    See step  6

  41. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    GTY720471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Apply seal packing to the transfer extension housing sub-assembly, as shown in the illustration.
      TEXT IN ILLUSTRATION

      *1 Seal Packing

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    2. Apply adhesive to the bolt threads.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the transfer extension housing sub-assembly with the 5 bolts.
      GTY692008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  42. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Install the speedometer driven hole cover sub-assembly with the bolt.

      Torque: 12 N.m (117 kgf/cm, 8 ft.lbf) 

  43. INSTALL FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    GTY715556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a hammer, tap in a new front transfer output shaft companion flange oil seal.
      • SST: 09950-60010 
        1. 09951-00320
      • SST: 09950-70010 
        1. 09951-07100
  44. INSTALL REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL 
    1. Tap in a new rear transfer output shaft companion flange oil seal using the same procedure as for the front transfer output shaft companion flange oil seal.
      • SST: 09950-60010 
        1. 09951-00320
      • SST: 09950-70010 
        1. 09951-07100
  45. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    GTY285742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the front output shaft companion flange sub-assembly onto the drive sprocket sub-assembly.
    2. Using SST to hold the front output shaft companion flange sub-assembly, install a new lock nut.
      • SST: 09330-00021 

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

      TEXT IN ILLUSTRATION

      Front
    3. Using a chisel and hammer, stake the lock nut.
      GTY715679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Securely stake the shaft to the lock nut groove.
      • Be careful not to damage the parts around the lock nut.
      • Do not apply excessive force to the shaft.
  46. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    GTY234336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the rear output shaft companion flange sub-assembly onto the drive sprocket sub-assembly.
    2. Using SST to hold the rear output shaft companion flange sub-assembly, install a new lock nut.
      • SST: 09330-00021 

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

      TEXT IN ILLUSTRATION

      Rear
    3. Using a chisel and hammer, stake the lock nut.
      GTY715679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Correct
      *b Incorrect
      NOTE:
      • Securely stake the shaft to the lock nut groove.
      • Be careful not to damage the parts around the lock nut.
      • Do not apply excessive force to the shaft.
  47. INSTALL FRONT TRANSFER BEARING RETAINER OIL SEAL 
    GTY717220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a hammer, tap in a new front transfer bearing retainer oil seal until its surface is flush with the retainer upper surface.
      • SST: 09950-60010 
        1. 09951-00590
      • SST: 09950-70010 
        1. 09951-07100
    2. Coat the lip of the oil seal with MP grease.
  48. INSTALL FRONT TRANSFER BEARING RETAINER SUB-ASSEMBLY 
    GTY687258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Apply seal packing to the front transfer bearing retainer sub-assembly, as shown in the illustration.
      TEXT IN ILLUSTRATION

      *1 Seal Packing

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    2. Apply adhesive to the bolt threads.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the front transfer bearing retainer sub-assembly with the 5 bolts.
      GTY692007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 12 N.m (117 kgf/cm, 8 ft.lbf) 

  49. INSTALL BREATHER OIL DEFLECTOR SUB-ASSEMBLY 
    1. Install the breather oil deflector sub-assembly.
  50. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY 
    GTY702224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the transfer case cover sub-assembly with the 4 bolts.

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

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