Transfer Assembly Disassembly

Drive Line. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
Gf1A Transfer. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT

  2. REMOVE TRANSFER CASE STRAIGHT PIN

  3. REMOVE TRANSFER CASE NO. 1 PLUG

  4. REMOVE TRANSFER CASE NO. 2 PLUG

  5. REMOVE TRANSFER DRAIN PLUG

  6. REMOVE TRANSFER CASE OIL SEAL LH

  7. REMOVE TRANSFER CASE OIL SEAL RH

  8. INSPECT RING GEAR BACKLASH

  9. REMOVE NO. 1 TRANSFER CASE COVER

  10. REMOVE TRANSFER RING GEAR

  11. REMOVE TRANSFER CASE STRAIGHT PIN

  12. REMOVE TRANSFER OUTPUT REAR SHAFT SUB-ASSEMBLY

  13. REMOVE TRANSFER DRIVEN PINION

  14. REMOVE TRANSFER OUTPUT REAR SHAFT DUST DEFLECTOR

  15. REMOVE TRANSFER DRIVEN PINION FRONT BEARING

  16. REMOVE TRANSFER OUTPUT SHAFT WASHER

  17. REMOVE RING GEAR MOUNTING CASE BEARING (for LH side)

  18. REMOVE RING GEAR MOUNTING CASE WASHER

  19. REMOVE RING GEAR MOUNTING CASE BEARING (for RH side)

  20. REMOVE TRANSFER RING GEAR MOUNTING CASE NO. 2 WASHER

  21. REMOVE SHAFT SNAP RING

  22. REMOVE TRANSFER RING GEAR MOUNTING CASE

  23. REMOVE BREATHER OIL DEFLECTOR

  24. REMOVE TRANSFER CASE BREATHER PLUG

Transfer Assembly -- Disassembly



1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. except K111F:
    Remove the 4 stud bolts.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. for K111F:
    Remove the 4 stud bolts.



2. REMOVE TRANSFER CASE STRAIGHT PIN


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. except K111F:
    Remove the 2 straight pins.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. for K111F:
    Remove the 2 straight pins.



3. REMOVE TRANSFER CASE NO. 1 PLUG

  1. Remove the No. 1 plug.

  1. Remove the gasket from the No. 1 plug.



4. REMOVE TRANSFER CASE NO. 2 PLUG


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Remove the No. 2 plug.

  1. Remove the gasket from the No. 2 plug.



5. REMOVE TRANSFER DRAIN PLUG


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Remove the drain plug.

  1. Remove the gasket from the drain plug.



6. REMOVE TRANSFER CASE OIL SEAL LH


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Using SST, tap out the oil seal from the case.

    SST
    09308-00010
    NOTICE:
    Do not damage the oil seal lip.


7. REMOVE TRANSFER CASE OIL SEAL RH


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using SST, tap out the oil seal from the case.

    SST
    09308-00010
    NOTICE:
    Do not damage the oil seal lip.


8. INSPECT RING GEAR BACKLASH


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Using a dial indicator, measure the backlash of the ring gear at 3 points.

    Standard backlash:
    0.10 to 0.20 mm (0.0039 to 0.0079 in.)
    If the backlash is not within the specified range, adjust the backlash or repair as necessary.


9. REMOVE NO. 1 TRANSFER CASE COVER


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 8 bolts.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a brass bar and hammer, tap out the cover from the case.



10. REMOVE TRANSFER RING GEAR


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the ring gear from the transfer case.



11. REMOVE TRANSFER CASE STRAIGHT PIN

  1. Remove the 2 straight pins from the transfer case.



12. REMOVE TRANSFER OUTPUT REAR SHAFT SUB-ASSEMBLY


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 5 bolts and transfer output rear shaft.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Using SST and a hammer, unstake the lock nut.

    SST
    09930-00010

  1. Remove the lock nut.



13. REMOVE TRANSFER DRIVEN PINION


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Using SST and a press, press out the driven pinion from the output shaft.

    SST
    09950-00020
    09950-60010(09951-00220)
    09950-70010(09951-07100)


14. REMOVE TRANSFER OUTPUT REAR SHAFT DUST DEFLECTOR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Using SST and a press, press out the dust deflector from the output rear shaft.

    SST
    09950-00020


15. REMOVE TRANSFER DRIVEN PINION FRONT BEARING


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Using SST and a press, press out the driven pinion from the bearing.

    SST
    09950-00020
    09950-60010(09951-00420)
    09950-70010(09951-07100)


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the O-ring from the bearing.



16. REMOVE TRANSFER OUTPUT SHAFT WASHER


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the washer from the transfer pinion gear.



17. REMOVE RING GEAR MOUNTING CASE BEARING (for LH side)


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Using SST, remove the bearing from the mounting case.

    SST
    09950-40011(09951-04010,09952-04010,09953-04030,09954-04010,09955-04061,09957-04010,09958-04011)
    09950-60010(09951-00540)


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Using SST and a hammer, tap out the bearing.

    SST
    09310-35010


18. REMOVE RING GEAR MOUNTING CASE WASHER


19. REMOVE RING GEAR MOUNTING CASE BEARING (for RH side)


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using SST, remove the bearing from the mounting case.

    SST
    09950-40011(09951-04010,09952-04010,09953-04020,09954-04010,09955-04061,09957-04010,09958-04011)
    09950-60010(09951-00540)

  1. Using SST and a hammer, tap out the bearing (race) from the cover.

    SST
    09636-20010


20. REMOVE TRANSFER RING GEAR MOUNTING CASE NO. 2 WASHER


21. REMOVE SHAFT SNAP RING


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Using a snap ring expander, remove the snap ring.



22. REMOVE TRANSFER RING GEAR MOUNTING CASE


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.Gf1A Transfer.Transfer System.Transfer Assembly Disassembly

  1. Using SST and a press, press out the ring gear from the mounting case.

    SST
    09950-60010(09951-00400)


23. REMOVE BREATHER OIL DEFLECTOR


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 bolts and oil deflector.



24. REMOVE TRANSFER CASE BREATHER PLUG


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the breather plug from the transfer case.