Transfer Case Assembly: Disassembly

1. Remove Vehicle Speed Sensor  .

   Torque: 11.5 N.m (115 kgf.cm, 8 ft.lbf) 

2. W/One touch 2-4 selector system and A/T: 

   Remove L4 Position Switch  .

   Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

3. W/O One touch 2-4 selector system: 

   Remove 4WD Position Switch  .

   Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

4. A/T: 

   Remove Neutral Position Switch  .

   Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

NOTE:
At the time of installation,check the following items.
• The input shaft and output shafts rotate smoothly.
• Shifting can be made smoothly to all position.
5. Remove Plugs Of Front Case  .

   Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

6. Remove Protector 

   Remove the 4 bolts and protector.

   Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

7. 3RZ-FE A/T: 

   Remove Shift Gear Head No. 1 And No. 2  .

   1. Using a pin punch and hammer, drive out the 2 slotted spring pins.
      Fig 1: Locating Slotted Spring Pins

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the 2 shift gear heads.
8. Remove Front Bearing Retainer 
   NOTE:

   At the time of installation, apply liquid sealer to the bolts.

   Sealant: 

   Part No.08833-00080, THREE BOND 1344, 

   LOCTITE 242 or equivalent  .

   Fig 2: Removing Front Bearing Retainer Bolts
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Remove the 5 bolts.

      Torque: 11.5 N.m (115 kgf.cm, 8 ft.lbf) 

   NOTE:
   At the time of installation, please refer to the following items.
   • Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the front bearing retainer.
   • Apply FIPG to the front bearing retainer.

     FIPG: 

     Part No. 08826-00090, 

     THREE BOND 1281 or equivalent  .

     Fig 3: Applying FIPG On Front Bearing Retainer

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a plastic hammer, tap the front bearing retainer and remove it.
NOTE: At the time of installation, install a new gasket.
9. 3RZ-FE A/T: 

   Remove upper cover, 2 gaskets and oil deflector  .

   Remove the 4 bolts, upper cover, 2 gaskets and oil deflector.

   Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

10. Except 3RZ-FE A/T: 

    Remove control retainer, gasket and oil deflector  .

    NOTE:

    At the time of installation, install a new gasket.

    1. Remove the 4 bolts, control retainer, gasket and oil deflector.

       Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    2. W/O One touch 2-4 selector system:

    Remove the select return spring from the control retainer.

11. Remove Front Companion Flange 
    NOTE:

    At the time of installation, stake a new lock nut.

    1. Using a chisel and hammer, loosen the staked part of the nut.
    2. Using SST to hold the flange, remove the companion flange lock nut.
       Fig 4: Removing Companion Flange Lock Nut

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       SST 09330-00021

       Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf) 

    3. Using SST, remove the companion flange.

       SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)

NOTE:
At the time of installation, please refer to the following items.
• Front companion flange bolts are slim.
• Rear companion flange bolts are thick.
Fig 5: Removing Companion Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Remove Rear Companion Flange 

    Remove the rear companion flange in the same way as the front companion flange.

13. Remove Extension Housing 
    NOTE:

    At the time of installation, apply liquid sealer to the bolts.

    Sealant: 

    Part No.08833-00080, THREE BOND 1344, 

    LOCTITE 242 or equivalent  .

    1. Remove the 5 bolts.

       Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

    NOTE:

    At the time of installation, please refer to the following items.

    • Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the extension housing.
    • Apply FIPG to the extension housing.
      Fig 6: Identifying FIPG On Extension Housing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      FIPG: 

      Part No.08826-00090, 

      THREE BOND 1281 or equivalent  .

    2. Using a plastic hammer, tap the extension housing and remove it.
14. Remove Vehicle Speed Sensor Drive Gear 
    NOTE:

    At the time of installation, please refer to the following item.

    Make sure to install the drive gear in the correct direction.

    1. Remove the vehicle speed sensor drive gear.
    2. Using a magnetic finger, remove the ball from the rear output shaft.
15. Separate Front Case And Rear Case 
    1. Remove the 12 bolts.

       Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 

    NOTE:

    At the time of installation, please refer to the following items.

    • Shift the high and low sleeve to low side (rear side) and assemble the front case and rear case.
    • Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the rear case.
    • Apply FIPG to the rear case.
      Fig 7: Identifying FIPG On Rear Case

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      FIPG: 

      Part No.08826-00090, 

      THREE BOND 1281 or equivalent  .

    2. Using a screwdriver, separate the front case and rear case.
16. Remove Straight Screw Plug, Spring And Locking Ball 
    NOTE:

    At the time of installation, apply liquid sealer to the plugs.

    Sealant: 

    Part No.08833-00080, THREE BOND 1344, 

    LOCTITE 242 or equivalent  .

    Fig 8: Removing Straight Screw Plug
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a hexagon wrench, remove the 1 or 2 screws.

       Torque: 18.6 N.m (190 kgf.cm, 14 ft.lbf) 

    2. Using a magnetic finger, remove the 1 or 2 springs and balls from the bolt hole.
    Fig 9: Removing Springs And Balls

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. W/One touch 2-4 selector system: 

    Remove high and low fork shaft, shift fork and shift head No. 2  .

    NOTE: Be careful not to damage the sealing surface.
    1. Mount the rear case in a vise.
    2. Using a pin punch and hammer, drive out the 2 slotted spring pins.
       Fig 10: Driving Out Slotted Spring Pins - W/One Touch 2-4 Selector System

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    At the time of installation, please refer to the following items.
    • Place the high and low shift fork into the groove of the clutch sleeve.
    • Make sure to install the shift fork and shift gear head No. 2 in the correct direction.
    Fig 11: Removing Shift Fork Components - W/One Touch 2-4 Selector System
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove high and low fork shaft, shift fork and shift gear head No. 2.
18. W/O One touch 2-4 selector system: 

    Remove front drive fork shaft, shift fork, spring and stopper  .

    NOTE: Be careful not to damage the sealing surface.
    1. Mount the rear case in a vise.
    NOTE:
    When the pin is removed from the front drive fork shaft, the shaft will spring loose if the pin punch is removed, so keep the pin punch inserted in the shaft hole.
    At the time of installation, please refer to the following items.
    • Use a pin punch and hammer, drive in the 2 slotted spring pins.
    • When installing the pin in the front drive fork shaft, push the shaft towards the rear case and install the pin while the spring is compressed.
    Fig 12: Driving Out Slotted Spring Pins - 3RZ-FE A/T (W/O One Touch 2-4 Selector System)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 13: Driving Out Slotted Spring Pins - Except 3RZ-FE A/T (W/O One Touch 2-4 Selector System)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 14: Driving In Slotted Spring Pins - 3RZ-FE A/T (W/O One Touch 2-4 Selector System)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 15: Driving In Slotted Spring Pins - 3RZ-FE A/T (W/O One Touch 2-4 Selector System)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, drive out the 2 slotted spring pins.
    3. Hold the front drive fork shaft in place by hand, when removing the pin punch.
       Fig 16: Removing Pin Punch By Holding Front Drive Fork Shaft

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    At the time of installation, please refer to the following items.
    • Place the front drive shift fork into the groove of the clutch sleeve.
    • Make sure to install the shift fork and stopper in the correct direction.
    Fig 17: Removing Front Drive Shift Fork Components - 3RZ-FE A/T
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 18: Removing Front Drive Shift Fork Components - Except 3RZ-FE A/T
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front drive fork shaft, shift fork, spring and stopper.
    NOTE:

    At the time of installation, apply gear oil to the straight pin and insert it into the case hole.

    Fig 19: Removing Straight Pin - W/O One Touch 2-4 Selector System
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. W/O One touch 2-4 selector system:

       Using a magnetic finger, remove the straight pin.

19. W/One touch 2-4 selector system: 

    Remove rear output shaft, driven sprocket, chain and front drive shift fork  .

    1. Remove the shift fork bolt.
       Fig 20: Removing Shift Fork Bolt - W/One Touch 2-4 Selector System

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Torque: 24 N.m (240 kgf.cm, 17 ft.lbf) 

    2. Using a snap ring expander, remove the snap ring.
       Fig 21: Removing Snap Ring - W/One Touch 2-4 Selector System

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    At the time of installation, please refer to the following items.
    • Place the front drive shift fork into the groove of the clutch sleeve.
    • Make sure to install the shift fork in the correct direction.
    • If necessary, heat the rear case to about 50 - 80°C (122 -176°F).
    3. Using a plastic hammer, tap the rear case while pulling the rear output shaft, driven sprocket and front drive shift fork.
    4. Remove the chain.
    Fig 22: Tapping Rear Case While Pulling Rear Output Shaft - W/One Touch 2-4 Selector System

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
At the time of installation, please refer to the following items.
• Place the high and low shift fork into the groove of the clutch sleeve.
• Make sure to install the shift fork in the correct direction.
Fig 23: Removing High And Low Fork Shaft And Shift Fork - 3RZ-FE A/T W/One Touch 2-4 Selector System
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 24: Removing High And Low Fork Shaft And Shift Fork - Except 3RZ-FE A/T W/One Touch 2-4 Selector System
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. W/O One touch 2-4 selector system: 

    Remove high and low fork shaft and shift fork  .

21. Remove rear output shaft, driven sprocket and chain  .
    1. Using a snap ring expander, remove the snap ring.
       Fig 25: Removing Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    At the time of installation, if necessary, heat the rear case to about 50-80°C (122-176°F).

    Fig 26: Tapping Rear Case With Pulling Rear Output Shaft And Driven Sprocket
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, tap the rear case with pulling the rear output shaft and driven sprocket.
    3. Remove the chain.
22. W/One touch 2-4 selector system: 

    Remove actuator assembly  .

    1. Using 2 screwdrivers and a hammer, remove the snap ring.
    2. Remove the 3 bolts and the actuator assembly.

       Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

       Fig 27: Removing Snap Ring To Remove Actuator Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    At the time of installation, coat a new O-ring with gear oil and install it to the actuator assembly.

    Fig 28: Removing O-Ring, 4WD Position Switch And Snap Ring From Actuator Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring, 4WD position switch and snap ring from the actuator assembly.

       Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

NOTE:
At the time of installation, please refer to the following items.
• Apply MP grease to the synchronizer ring.
• Align the synchronizer ring slots with the shifting keys, and install it on the high and low clutch hub.
Fig 29: Removing Synchronizer Ring From Input Shaft - M/T
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. M/T: 

    Remove synchronizer ring from input shaft  .

24. Remove separator with oil strainer and magnet  .

    Remove the 3 bolts and the separator with the oil strainer and magnet.

    Torque: 7.5 N.m (80 kgf.cm, 69 in.lbf) 

25. Remove oil pump body assembly  .

    Remove the 3 bolts and the oil pump body assembly.

    Torque: 7.5 N.m (80 kgf.cm, 69 in.lbf) 

26. Remove oil pump drive gear  .
    Fig 30: Removing Separator With Oil Strainer And Magnet

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. Remove planetary gear assembly with input shaft  .
    1. Using a snap ring expander, remove the snap ring.
       Fig 31: Removing Planetary Gear Assembly Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    At the time of installation, If necessary, heat the front case to about 50-80°C (122-76°F).

    Fig 32: Pulling Out Planetary Gear Assembly With Input Shaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull out the planetary gear assembly with the input shaft.
28. Remove low gear spline piece  .
    NOTE:

    At the time of installation, be sure the end gap of the snap ring is not aligned with cutout portion of the planetary carrier.

    Fig 33: Removing Low Gear Spline Piece Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the snap ring.
    2. Remove the low gear spline piece.
    Fig 34: Removing Low Gear Spline Piece

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:

At the time of installation, apply gear oil to the needle roller bearing.

Fig 35: Identifying Needle Roller Bearingt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. Remove needle roller bearing from input shaft  .
30. Remove input shaft stopper and thrust bearing  .
    NOTE:

    At the time of installation, Select a snap ring that will allow 0.05 - 0.15 mm (0.0020 - 0.0059 in.) axial play.

    Fig 36: Removing Input Shaft Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, remove the snap ring.
       SNAP RING THICKNESS REFERENCE
       
       

       Mark	Thickness MM (IN.)
       A	2.10 - 2.15(0.0827 - 0.0846)
       B	2.15 - 2.20(0.0846 - 0.0866)
       C	2.20 - 2.25(0.0866 - 0.0886)
       D	2.25 - 2.30(0.0886 - 0.0906)
       E	2.30 - 2.35 (0.0906 - 0.0925)
       F	2.35 - 2.40 (0.0925 - 0.0945)
       G	2.40 - 2.45 (0.0945 - 0.0965)
       H	2.45 - 2.50 (0.0965 - 0.0984)
       J	2.50 - 2.55(0.0984 - 0.1004)
       K	2.55 - 2.60(0.1004 - 0.1024)
       L	2.60 - 2.65(0.1024 - 0.1043)
       M	2.65 - 2.70(0.1043 - 0.1063)
       N	2.70 - 2.75(0.1063 - 0.1083)
       P	2.75 - 2.80(0.1083 - 0.1102)
       Q	2.80 - 2.85(0.1102 - 0.1122)
       R	2.85 - 2.90(0.1122 - 0.1142)
       S	2.90 - 2.95(0.1142 - 0.1161)
       T	2.95 - 3.00(0.1161 - 0.1181)
       U	3.00 - 3.05(0.1181 - 0.1201)

    NOTE:

    At the time of installation, apply gear oil to the input gear stopper and thrust washer.

    Fig 37: Removing Input Gear Stopper, Thrust Washer And Ball
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the input gear stopper, thrust washer and ball.
31. Remove input shaft, thrust needle roller bearing and thrust race  .
    Fig 38: Removing Input Shaft, Thrust Needle Roller Bearing And Thrust Race

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. Remove planetary ring gear 
    NOTE:

    At the time of installation, Be sure the end gap of the snap ring is not aligned with the upper side of the case.

    Fig 39: Removing Planetary Ring Gear Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the snap ring.
    NOTE:

    At the time of installation, apply liquid sealer to the plug.

    Sealant: 

    Part No.08833-00080, THREE BOND 1344, 

    LOCTITE 242 or equivalent  .

    Fig 40: Removing Plug, Spring And Pin
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the plug, spring and pin.

       Torque: 18.6 N.m (190 kgf.cm, 14 ft.lbf) 

    NOTE:

    At the time of installation, Make sure to install the ring gear in the correct direction.

    Fig 41: Removing Planetary Ring Gear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the planetary ring gear.
33. Inspect switches  .

Check that there is continuity between terminals.

Fig 42: Checking Continuity Between Switch Terminals In Push Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 43: Checking Continuity Between Switch Terminals In Free Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If operation is not as specified, replace the switch.