Transfer Assembly: Disassembly

REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY
1. Remove the bolt and bracket.
Fig 1: Locating Propeller Shaft Heat Insulator Bracket Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OIL PUMP PLATE
1. Remove the 4 bolts, oil pump plate and oil pump driven rotor.
  NOTE: Do not drop the oil pump driven rotor.
2. Remove the O-ring from the oil pump plate.
  
  Fig 2: Locating Transfer Oil Pump Plate Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the transfer oil seal ring from the input shaft.
  
  Fig 3: Locating Transfer Oil Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the oil pump drive rotor from the input shaft.
Fig 4: Identifying Oil Pump Drive Rotor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE STRAIGHT PIN
1. Remove the 2 straight pins.
NOTE: Do not drop the straight pins.

Fig 5: Identifying Transfer Case Straight Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE PLUG
1. Using a 10 mm hexagon wrench, remove the case plug, compression spring, ball and relief valve seat.
Fig 6: Locating Transfer Case Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OIL PUMP PLATE OIL SEAL
1. Using a screwdriver, pry out the oil seal from the oil pump plate.
  NOTE: Be careful not to damage the oil seal and oil pump plate contact surfaces.
  
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 7: Prying Out Oil Seal From Oil Pump Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Using SST and a hammer, release the staked part of the nut.
  SST 09930-00010 (09931-00010, 09931-00020)
  NOTE:
  - Be sure to use SST with the tapered surface facing the shaft.
  - Do not grind the tip of SST with a grinder, etc.
  - Completely loosen the staked part of the nut when removing it.
  - Do not damage the threads of the transfer driven sprocket.
  Fig 8: Staking Part Of Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the companion flange, remove the lock nut.
  SST 09330-00021
  
  Fig 9: Removing Companion Flange Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, remove the companion flange.
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
4. Remove the O-ring from the companion flange.
REMOVE TRANSFER CASE FRONT OIL SEAL (See REPLACEMENT )

Fig 10: Removing Companion Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
1. Using SST and a hammer, release the staked part of the nut.
  SST 09930-00010 (09931-00010, 09931-00020)
  NOTE:
  - Be sure to use SST with the tapered surface facing the shaft.
  - Do not grind the tip of SST with a grinder, etc.
  - Completely loosen the staked part of the nut when removing it.
  - Do not damage the threads of the rear transfer output shaft.
  Fig 11: Staking Part Of Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST to hold the companion flange, remove the lock nut.
  SST 09330-00021
  
  Fig 12: Removing Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, remove the companion flange.
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
4. Remove the O-ring from the companion flange.
REMOVE TRANSFER CASE REAR OIL SEAL (See REPLACEMENT )

Fig 13: Removing Companion Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TRANSFER CASE PLUG
1. Remove the plug, compression spring and pin.
Fig 14: Identifying Transfer Case Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE PLUG
1. Using a 6 mm hexagon wrench, remove the plug.
Fig 15: Locating Transfer Case Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR TRANSFER CASE ASSEMBLY
1. Remove the 14 bolts.
2. Remove the rear transfer case.
  HINT:
  
  If necessary, tap the rear transfer case with a plastic-faced hammer to remove it.
  
  Fig 16: Locating Rear Transfer Case Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING
1. Remove the needle roller bearing and spacer from the output shaft.
Fig 17: Identifying Needle Roller Bearing And Spacer From Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 TRANSFER GEAR SHIFT FORK
1. Using 2 screwdrivers and a hammer, tap off the 4 shift fork shaft snap rings.
  
  Fig 18: Locating Shift Fork Shaft Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt. Then remove the No. 2 gear shift fork together with the high and low clutch sleeve from the shift actuator.
Fig 19: Locating Gear Shift Fork Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY
1. Remove the No. 1 gear shift fork bolt.
  
  Fig 20: Locating Gear Shift Fork Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 bolts.
  
  Fig 21: Locating Transfer Shift Actuator Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the shift actuator, No. 1 gear shift fork, washer, and straight pin from the rear transfer case.
  NOTE: Take care not to drop the No. 1 gear shift fork, washer, and straight pin.
  
  Fig 22: Identifying Shift Actuator, Gear Shift Fork, Washer, And Straight Pin From Rear Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the O-ring from the shift actuator.
Fig 23: Identifying O-Ring From Shift Actuator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR TRANSFER OUTPUT SHAFT ASSEMBLY
1. Using a snap ring expander, expand the snap ring as shown in the illustration (Fig 24).
  
  Fig 24: Expanding Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic-faced hammer, carefully tap the rear transfer case, and remove the output shaft together with the drive chain and driven sprocket.
3. Remove the output shaft and driven sprocket from the drive chain.
  NOTE: Do not drop the output shaft washers.
  
  Fig 25: Tapping Rear Transfer Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a snap ring expander, remove the snap ring from the rear transfer case.
Fig 26: Identifying Snap Ring From Rear Transfer Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE CLUTCH SLEEVE
1. Remove the clutch sleeve from the output shaft.
Fig 27: Identifying Front Drive Clutch Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SIDE GEAR SHAFT HOLDER BEARING
1. Using a screwdriver, remove the snap ring.
  
  Fig 28: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the bearing.
  SST 09308-00010
  
  Fig 29: Removing Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OIL SEPARATOR SUBASSEMBLY
1. Remove the 3 bolts and oil separator.
2. Remove the O-ring from the oil separator.
Fig 30: Locating Oil Separator Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER CASE MAGNET
1. Remove the magnet from the oil separator.
Fig 31: Locating Magnet From Oil Separator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT SHAFT ASSEMBLY
1. Using a 14 mm hexagon wrench, remove the 2 case plugs from the front transfer case.
  
  Fig 32: Locating Front Transfer Case Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, expand the snap ring as shown in the illustration (Fig 33). Then remove the input shaft from the front transfer case.
Fig 33: Expanding Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER LOW PLANETARY RING GEAR
1. Using a screwdriver, remove the snap ring. Then remove the low planetary ring gear from the front transfer case.
  
  Fig 34: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, remove the snap ring from the front transfer case.
Fig 35: Identifying Snap Ring From Front Transfer Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVEN SPROCKET BEARING
1. Using a screwdriver, remove the snap ring. Then remove the bearing from the front transfer case.
Fig 36: Identifying Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 SYNCHRONIZER RING
1. Remove the synchronizer ring from the input shaft.
Fig 37: Identifying Synchronizer Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING
1. Remove the seal ring from the input shaft.
Fig 38: Identifying Seal Ring From Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT SHAFT BEARING
1. Using a snap ring expander, remove the snap ring.
  
  Fig 39: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press out the bearing.
  SST 09555-55010, 09950-60010 (09951-00490), 09950-70010 (09951-07100)
  
  NOTE: Be careful not to drop or damage the input shaft, low planetary gear and low planetary gear bearings.
  
  HINT:
  
  When the bearing is removed, the input shaft, low planetary gear, and 2 low planetary gear bearings will come off.
  
  Fig 40: Pressing Out Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH
1. Using SST, remove the bush.
  SST 09387-00041 (09387-01021, 09387-01030, 09387-01040)
  
  Fig 41: Removing Transfer Input Shaft Bimetal Formed Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER INPUT SHAFT PLUG
1. Using SST and a hammer, tap out the input shaft plug.
  SST 09950-70010 (09951-07150), 09950-60010 (09951-00300)
  
  Fig 42: Tapping Out Input Shaft Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT SHAFT WASHER
1. Remove the 2 output shaft washers from the output shaft.
Fig 43: Identifying Transfer Output Shaft Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER
1. Using 2 screwdrivers and a hammer, tap off the snap ring.
  
  Fig 44: Removing Transfer Output Shaft Spacer And Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the output shaft spacer from the output shaft.
  
  Fig 45: Identifying Output Shaft Spacer From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the seal ring from the output shaft spacer.
  
  Fig 46: Identifying Seal Ring From Output Shaft Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the straight pin from the output shaft.
Fig 47: Identifying Straight Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER DIFFERENTIAL CASE
1. Remove the center differential case from the output shaft.
  
  Fig 48: Identifying Center Differential Case From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a snap ring expander, remove the snap ring.
  
  Fig 49: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the synchromesh shifting key spring and No. 2 synchromesh shifting keys from the center differential case.
  
  Fig 50: Identifying Synchromesh Shifting Keys From Center Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, remove the needle roller bearing.
  SST 09308-00010
  
  Fig 51: Removing Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, remove the needle roller bearing.
  SST 09387-00041 (09387-01021, 09387-01030, 09387-01040)
  
  Fig 52: Removing Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER OUTPUT SHAFT SPACER
1. Using 2 screwdrivers and a hammer, tap off the snap ring.
  
  Fig 53: Removing Transfer Output Shaft Spacer And Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the output shaft spacer from the output shaft.
  
  Fig 54: Identifying Output Shaft Spacer From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the straight pin from the output shaft.
Fig 55: Identifying Straight Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVE SPROCKET SUBASSEMBLY
1. Remove the drive sprocket from the output shaft.
Fig 56: Identifying Drive Sprocket From Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSFER DRIVE SPROCKET BEARING
1. Remove the bearing from the output shaft.
Fig 57: Identifying Transfer Drive Sprocket Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR TRANSFER OUTPUT SHAFT
1. Using SST and a press, press out the bearing.
  SST 09527-10011
  
  NOTE: Be careful not to drop or damage the output shaft.
  
  Fig 58: Removing Rear Transfer Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the needle roller bearing from the output shaft.
Fig 59: Identifying Needle Roller Bearing From Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002