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Home >> Toyota >> 2022 >> 4Runner TRD Pro >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Transfer Case (VF2CM) - Service Information) >> Transfer Assembly >> Disassembly [08/2019 - ] >> Procedure

Disassembly [08/2019 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE ACTUATOR BREATHER HOSE 
    1. GTY568131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disconnect the connection to the transfer shift actuator assembly, detach the 2 clamps, and then remove the actuator breather hose.

  2. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY 
    1. Remove the 4 bolts and transfer case cover sub-assembly.
      GTY708997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the breather oil deflector.
      GTY708995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Front Side) 
    1. Using a chisel and hammer, loosen the staked part of the transfer output shaft companion flange nut.
      NOTE:
      • Completely loosen the staked part of the lock nut when removing it.
      • Do not damage the threads of the driven sprocket.
    2. Using SST to hold the output shaft companion flange sub-assembly, remove the transfer output shaft companion flange nut.
      • SST: 09330-00021 
      GTY904463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
    3. Using SST, remove the output shaft companion flange sub-assembly.
      GTY907856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04031
        6. 09957-04010
        7. 09958-04011
      NOTE:

      Apply a lubricant to the threads and end of SST.

      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
    4. Using SST and hammer, remove the transfer output shaft companion flange oil seal.
      • SST: 09950-60011 
        1. 09951-00220
        2. 09951-00290
        3. 09952-06010
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

      Be careful not to damage the transfer output shaft companion flange oil seal and output shaft companion flange sub-assembly contact surfaces.

      GTY927589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSFER CASE OIL SEAL 

    See step  7

  5. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Rear Side) 
    1. Using a chisel and hammer, loosen the staked part of the transfer output shaft companion flange nut.
      NOTE:
      • Completely loosen the staked part of the transfer output shaft companion flange nut when removing it.
      • Do not damage the threads of the rear transfer output shaft.
    2. Using SST to hold the output shaft companion flange sub-assembly, remove the transfer output shaft companion flange nut and transfer output shaft O-ring.
      • SST: 09330-00021 
      GTY848925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
    3. Using SST, remove the output shaft companion flange sub-assembly.
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04030
        4. 09954-04010
        5. 09955-04031
        6. 09957-04010
        7. 09958-04011
      GTY854953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Apply a lubricant to the threads and end of SST.

      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
  6. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 

    See step  4

  7. REMOVE TRANSFER EXTENSION HOUSING 
    1. Remove the 5 bolts and transfer extension housing.

      HINT: 

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

      GTY708987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSFER OUTPUT SHAFT WASHER 
    1. Remove the 2 transfer output shaft washers.
      GTY863894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Output Shaft Washer
      *2 No. 2 Transfer Output Shaft Spacer
    2. Remove the No. 2 transfer output shaft spacer.
  9. REMOVE NO. 1 TRANSFER CASE PLUG 
    1. Remove the No. 1 transfer case plug (filler plug) and No. 1 transfer case gasket.
      GTY866033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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. Remove the transfer drain plug and transfer drain plug gasket.
  10. REMOVE REAR TRANSFER CASE 
    1. Remove the 12 bolts and 4 brackets.
      GTY869130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bracket
    2. Remove the rear transfer case.

      HINT: 

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

  11. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Remove the 3 bolts and transfer oil separator sub-assembly.
      GTY709021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the transfer case magnet.
  12. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Remove the 3 bolts and transfer oil pump body sub-assembly.
      GTY709025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the transfer oil pump body O-ring.
      TEXT IN ILLUSTRATION

      *a Protective Tape
      GTY894581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the transfer oil pump body sub-assembly.

      HINT: 

      Tape the screwdriver tip before use.

    3. Remove the transfer oil pump gear.
      GTY709004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSFER FRONT BEARING RETAINER SUB-ASSEMBLY 
    1. Remove the 5 bolts and transfer front bearing retainer sub-assembly.
      GTY708996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  14. REMOVE TRANSFER FRONT BEARING TYPE T OIL SEAL 
    1. Using a screwdriver and hammer, remove the transfer front bearing type T oil seal.
      TEXT IN ILLUSTRATION

      *a Protective Tape
      NOTE:

      Be careful not to damage the transfer front bearing type T oil seal and transfer front bearing retainer sub-assembly contact surfaces.

      HINT: 

      Tape the screwdriver tip before use.

      GTY939453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSFER LOW PLANETARY GEAR ASSEMBLY 
    1. Using a snap ring expander, remove the transfer low planetary gear bearing shaft snap ring.
      GTY709007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the transfer low planetary gear assembly with the transfer input shaft.
      GTY709008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE TRANSFER CASE PLUG 
    1. Remove the transfer case plug, transfer case compression spring and pin.
      GTY907911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Case Plug
      *2 Transfer Case Compression Spring
      *3 Pin
  17. REMOVE TRANSFER LOW PLANETARY RING GEAR 
    1. Using a screwdriver, remove the transfer low planetary ring gear hole snap ring.
      TEXT IN ILLUSTRATION

      *a Protective Tape
      GTY913524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the front transfer case.

      HINT: 

      Tape the screwdriver tip before use.

    2. Remove the transfer low planetary ring gear.
  18. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Using a screwdriver, remove the transfer low planetary gear shaft snap ring.
      TEXT IN ILLUSTRATION

      *a Protective Tape
      GTY920145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the transfer low planetary gear assembly.

      HINT: 

      Tape the screwdriver tip before use.

    2. Remove the transfer low planetary gear spline piece.
      GTY709012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the transfer output shaft front needle roller bearing.
      GTY709009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE TRANSFER INPUT SHAFT 
    1. Using a snap ring expander, remove the transfer input gear stopper shaft snap ring.
      GTY735847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the transfer input gear stopper and transfer input gear stopper ball.
      GTY869180Courtesy 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
    3. Remove the manual transfer planetary carrier washer.
    4. Remove the transfer input shaft, transfer low planetary gear bearing and No. 1 transfer thrust bearing race.
      GTY871497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transfer Input Shaft
      *2 Transfer Low Planetary Gear Bearing
      *3 No. 1 Transfer Thrust Bearing Race
  20. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    1. Remove the 2 No. 1 transfer input shaft seal rings.
      GTY735857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSFER INPUT SHAFT BEARING 
    1. Using a snap ring expander, remove the transfer input bearing shaft snap ring.
      GTY709063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the transfer input shaft bearing.
      • SST: 09555-55010 
      • SST: 09950-00030 
      • SST: 09950-60021 
        1. 09951-00630
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
      GTY886395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the transfer low planetary gear assembly.
      • Apply a lubricant to the threads and end of SST.
  22. REMOVE TRANSFER LOW PLANETARY GEAR BEARING 
    1. Using SST, remove the transfer low planetary gear bearing.
      GTY892706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09527-10011 
      • SST: 09612-65014 
        1. 09612-01050
        2. 09612-01060
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
      NOTE:

      Hook SST securely between the bearing and transfer low planetary gear.

  23. REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT 
    NOTE:
    • When using a vise, place aluminum plates between the part and vise.
    • When using a vise, do not overtighten it.
    1. Type A:
      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
      1. Using a 6 mm hexagon wrench, remove the 2 shift detent ball spring plugs.
    2. Type B:
      1. Remove the 2 shift detent ball spring plugs.
    3. Using a magnet hand, remove the 2 shift detent ball compression springs and 2 shift detent balls.
    4. Using 2 screwdrivers and a hammer, remove the 2 transfer gear shift fork shaft snap rings.
      GTY568032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Use a piece of cloth to prevent the transfer gear shift fork shaft snap rings from flying off.

    5. Remove the bolt and transfer shift shaft stopper.
      GTY708993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. To remove 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.
      GTY936782Courtesy 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
    7. Remove the transfer front drive shift fork shaft.
    8. Using a magnet hand, remove the 2 shift interlock pin or rollers.
      GTY709015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REAR TRANSFER OUTPUT SHAFT, TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVEN SPROCKET 
    NOTE:
    • When using a vise, place aluminum plates between the part and vise.
    • When using a vise, do not overtighten it.
    1. Using 2 screwdrivers and a hammer, remove the transfer gear shift fork shaft snap ring.

      HINT: 

      • Use a piece of cloth to prevent the transfer gear shift fork shaft snap ring from flying off.
      • Remove only the transfer gear shift fork shaft snap ring on the front side of the transfer shift actuator shaft.
      GTY568067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, remove the transfer output shaft - shaft snap ring.
      GTY735849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic-faced hammer, carefully tap the rear transfer case, and remove the transfer output shaft rear, 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
  25. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY 
    1. Using 2 screwdrivers and a hammer, remove the transfer gear shift fork shaft snap ring.
      GTY568066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Use a piece of cloth to prevent the transfer gear shift fork shaft snap ring from flying off.

    2. Remove the 3 bolts and transfer shift actuator assembly.
      GTY709022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE TRANSFER DRIVEN SPROCKET BEARING 
    1. for Front Side:

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

      • SST: 09555-55010 
      • SST: 09950-60011 
        1. 09951-00210
      • SST: 09950-70010 
        1. 09951-07100
      GTY854257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to drop or damage the driven sprocket.

    2. for Rear Side:

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

      GTY860212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09555-55010 
      • SST: 09950-60011 
        1. 09951-00270
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

      Be careful not to drop or damage the driven sprocket.

  27. REMOVE TRANSFER CLUTCH HUB 
    1. Remove the transfer high and low clutch sleeve.
    2. Using a snap ring expander, remove the transfer clutch hub shaft snap ring.
      GTY709068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, remove the transfer clutch hub.
      GTY909815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09527-10011 
      NOTE:

      Be careful not to drop or damage the rear transfer output shaft.

  28. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY 
    1. Using SST and a press, remove the rear transfer output shaft radial ball bearing.
      GTY913206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09555-55010 
      NOTE:

      Be careful not to drop or damage the rear transfer output shaft.

    2. Remove the No. 1 transfer output shaft spacer.
      GTY846949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Transfer Output Shaft Spacer
      *2 Needle Roller Bearing
      *3 Transfer Drive Sprocket Sub-assembly
    3. Remove the needle roller bearing.
    4. Remove the transfer drive sprocket sub-assembly.
  29. REMOVE TRANSFER SYNCHRONIZER RING SET (w/ A.D.D.) 
    1. Remove the transfer synchronizer ring set.
      GTY568072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FRONT DRIVE CLUTCH SLEEVE 
    1. GTY859043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the front drive clutch sleeve.

      TEXT IN ILLUSTRATION

      *1 Front Drive Clutch Sleeve
      *2 Transfer Synchromesh Shifting Key Spring
      *3 No. 1 Synchromesh Shifting Key
      NOTE:

      w/ A.D.D.:

      Be careful not to drop the 3 No. 1 synchromesh shifting keys.

    2. w/ A.D.D.:

      Remove the 2 transfer synchromesh shifting key springs and 3 No. 1 synchromesh shifting keys.

  31. REMOVE TRANSFER DRIVE CLUTCH HUB 
    1. Using SST and a press, remove the transfer drive clutch hub.
      • SST: 09527-10011 
      NOTE:

      Be careful not to drop or damage the rear transfer output shaft.

      GTY862805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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