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Home >> Toyota >> 2019 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 36 (Transfer Case (Service Information) (Except Hybrid)) >> Transfer Assembly >> Disassembly [12/2013 - 11/2015] >> Procedure

Disassembly [12/2013 - 11/2015]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. Remove the 4 transfer and transaxle setting stud bolts from the transfer case.
      GTY252970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 2 TRANSFER CASE PLUG 
    1. Remove the No. 2 transfer case plug from the transfer case.
      GTY428004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the No. 2 transfer case plug.
  3. REMOVE NO. 1 TRANSFER CASE PLUG 
    1. Remove the No. 1 transfer case plug from the transfer case.
      GTY428009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the No. 1 transfer case plug.
  4. REMOVE TRANSFER DRAIN PLUG 
    1. Remove the transfer drain plug from the transfer case.
      GTY428008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the transfer drain plug.
  5. REMOVE TRANSFER CASE BREATHER PLUG 
    1. Using a screwdriver, remove the transfer case breather plug from the transfer case cover sub-assembly.
      GTY138617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Remove the 8 bolts from the transfer case cover sub-assembly.
      GTY435596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the transfer case cover sub-assembly from the transfer case.
      GTY226553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Place the brass bar on the rib protruding from the transfer case cover sub-assembly.

  7. REMOVE BREATHER OIL DEFLECTOR 
    1. Remove the bolt and breather oil deflector from the transfer case cover sub-assembly.
      GTY242674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 4 transfer case straight pins from the transfer case.
      GTY435597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. SECURE TRANSFER ASSEMBLY 
    1. Attach the transfer assembly to the overhaul attachment.
  10. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR 
    1. Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.
      GTY227909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing sub-assembly.
      GTY434649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
      NOTE:

      Be careful not to damage the transfer extension housing type T oil seal contact surface or the inside surface of the transfer extension housing type T oil seal.

  12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 4 bolts from the transfer case.
      GTY455554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case.
      GTY244697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT PRELOAD 

    See step  1

  14. INSPECT RING GEAR BACKLASH 

    See step  2

  15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION 

    See step  3

  16. REMOVE TRANSFER CASE OIL SEAL 
    1. Using SST, remove the transfer case oil seal from the transfer case.
      GTY444839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
      NOTE:

      Do not damage the transfer case oil seal contact surface to the transfer case.

  17. REMOVE TRANSFER CASE OIL SEAL RH 
    1. Using SST, remove the transfer case oil seal RH from the transfer case.
      GTY436270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
      NOTE:

      Do not damage the transfer case oil seal RH contact surface to the transfer case.

  18. REMOVE BEARING CAP 
    1. Remove the 2 bolts and bearing cap from the transfer case.
      GTY442479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER 
    1. Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer from the transfer case.
      GTY443173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Transfer Output Shaft Spacer
      *a Screwdriver
      *b Piece of Cloth
      • SST: 09504-22012 
      NOTE:

      Do not damage the transfer case.

  20. REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER 
    1. Remove No. 2 transfer ring gear mounting case washer from the transfer case.
  21. REMOVE TRANSFER RING GEAR MOUNTING CASE 
    1. Remove the transfer ring gear mounting case from the transfer case.
      GTY452960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE DRIVEN PINION 
    1. Using SST and a hammer, unstake the gear nut.
      GTY454598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09930-00010 

      HINT: 

      • Use SST with the flat side facing outward.
      • Do not machine the tip of SST with a grinder, etc.
    2. Using SST, remove the gear nut.
      GTY454056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09326-2001109556-16030 
    3. Using a press, press out the driven pinion, rear transfer driven pinion bearing (inner race) and transfer pinion bearing spacer.
      GTY438451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Transfer Driven Pinion Bearing (inner race)
      *2 Transfer Pinion Bearing Spacer
      *3 Driven Pinion
      NOTE:
      • Place a piece of cloth under the transfer case to prevent the driven pinion from dropping out of the rear transfer driven pinion bearing (inner race).
      • Use wooden blocks or similar objects under the case to keep it level.
  23. REMOVE FRONT TRANSFER DRIVEN PINION BEARING 
    1. Using SST and a press, remove the front transfer driven pinion bearing (inner race) from the transfer ring gear mounting case.
      GTY447114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-00020 
      NOTE:
      • Do not deform the cage of the front transfer driven pinion bearing (inner race) (when reusing the front transfer driven pinion bearing (inner race)).
    2. Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the front transfer driven pinion bearing (outer race) to remove it from the transfer case.
      GTY242641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSFER OUTPUT SHAFT WASHER 
    1. Remove the transfer output shaft washer from the transfer case.
  25. REMOVE RING GEAR MOUNTING CASE BEARING 
    1. for RH side:
      1. Remove the ring gear mounting case bearing (outer race) from the transfer ring gear mounting case.
      2. Using SST, remove the ring gear mounting case bearing (inner race) from the transfer ring gear mounting case.
        GTY438466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Turn
        *b Hold
        • SST: 09950-40011 
          1. 09951-04010
          2. 09952-04010
          3. 09953-04020
          4. 09954-04010
          5. 09955-04061
          6. 09957-04010
          7. 09958-04011
        • SST: 09950-60010 
          1. 09951-00440
        NOTE:
        • Use SST (09953-04020) after applying grease to its threads and tip.
        • Do not deform the cage of the ring gear mounting case bearing (inner race) (when reusing the ring gear mounting case bearing (inner race)).
        • Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the ring gear mounting case bearings).
    2. for LH side:
      1. Using SST, remove the ring gear mounting case bearing (inner race) from the transfer ring gear mounting case.
        GTY440886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Turn
        *b Hold
        • SST: 09950-40011 
          1. 09951-04010
          2. 09952-04010
          3. 09953-04020
          4. 09954-04010
          5. 09955-04061
          6. 09957-04010
          7. 09958-04011
        • SST: 09950-60010 
          1. 09951-00400
        NOTE:
        • Use SST (09953-04020) after applying grease to its threads and tip.
        • Do not deform the cage of the ring gear mounting case bearing (inner race) (when reusing the ring gear mounting case bearing (inner race)).
        • Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the ring gear mounting case bearings).
      2. Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the ring gear mounting case bearing (outer race) to remove it from the transfer case.
        GTY242647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the ring gear mounting case plate washer.
  26. INSPECT RUNOUT OF RING GEAR 

    See step  4

  27. REMOVE RING GEAR 
    1. Put matchmarks on the transfer ring gear mounting case and ring gear.
      GTY453603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    2. Remove the 12 bolts from the ring gear.
    3. Using a plastic hammer, remove the ring gear to separate it from the transfer ring gear mounting case.
      GTY299182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the ring gear teeth.

  28. INSPECT TRANSFER RING GEAR MOUNTING CASE 

    See step  5

  29. REMOVE REAR TRANSFER DRIVEN PINION BEARING (OUTER RACE) 
    1. Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the rear transfer driven pinion bearing (outer race) to remove it from the transfer case.
      GTY233817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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