INSTALL REAR TRANSFER OUTPUT SHAFT

INSTALL TRANSFER DRIVE SPROCKET BEARING

INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

INSTALL TRANSFER OUTPUT SHAFT SPACER

INSPECT TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

INSTALL CENTER DIFFERENTIAL CASE

INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER

INSTALL TRANSFER OUTPUT SHAFT WASHER

INSTALL TRANSFER INPUT SHAFT PLUG

INSTALL TRANSFER INPUT SHAFT BIMETAL FORMED BUSH

INSTALL TRANSFER INPUT SHAFT BEARING

INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING

INSTALL TRANSFER DRIVEN SPROCKET BEARING

INSTALL TRANSFER LOW PLANETARY RING GEAR

INSTALL INPUT SHAFT ASSEMBLY

INSTALL TRANSFER CASE MAGNET

INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY

INSTALL SIDE GEAR SHAFT HOLDER BEARING

INSTALL FRONT DRIVE CLUTCH SLEEVE

INSTALL REAR TRANSFER OUTPUT SHAFT ASSEMBLY

INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY

INSTALL NO. 2 TRANSFER GEAR SHIFT FORK

INSTALL FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING

INSTALL NO. 1 SYNCHRONIZER RING (for Manual Transmission)

INSTALL REAR TRANSFER CASE ASSEMBLY

INSTALL TRANSFER CASE PLUG

INSTALL NO. 1 TRANSFER CASE PLUG

INSTALL TRANSFER CASE REAR OIL SEAL

INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

INSTALL TRANSFER CASE FRONT OIL SEAL

INSTALL TRANSFER OUTPUT SHAFT DUST DEFLECTOR

INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

INSTALL TRANSFER OIL PUMP PLATE OIL SEAL

INSTALL TRANSFER CASE PLUG

INSTALL TRANSFER CASE STRAIGHT PIN

INSTALL TRANSFER OIL PUMP PLATE

INSTALL PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY

Install a new needle roller bearing.

Using SST and a press, press in a new bearing.

• SST
• 09527-10011

• NOTICE:

• Set the snap ring groove of the bearing to the front side.

Install the bearing to the output shaft.

Install the drive sprocket to the output shaft.

Install the straight pin to the output shaft.

Align the straight pin with the straight pin groove of the output shaft spacer, and slide on the output shaft spacer.

Using a screwdriver and hammer, tap on the snap ring.

Using a feeler gauge, measure the drive sprocket thrust clearance.

• Standard Clearance:
• 0.10 to 0.47 mm (0.00394 to 0.0185 in.)

• Maximum Clearance:
• 0.47 mm (0.0185 in.)

If the clearance is more than the maximum, replace the drive sprocket sub-assembly.

Using SST and a hammer, tap in a new needle roller bearing until its surface is 0 to 0.5 mm (0 to 0.0197 in.) from the center differential case upper surface.

• SST
• 09950-60020(09951-00710)
  09950-70010(09951-07100)

• NOTICE:

Using SST and a hammer, tap in a new needle roller bearing until its surface is 1.5 to 2.0 mm (0.0591 to 0.0787 in.) from the center differential case upper surface.

• SST
• 09950-60010(09951-00460)
  09950-70010(09951-07100)

• NOTICE:

for Manual Transmission:

Install the synchromesh shifting key spring and No. 2 synchromesh shifting keys as shown in the illustration.

for Manual Transmission:

Using a snap ring expander, install the snap ring.

Install the center differential case to the output shaft.

Install the straight pin to the output shaft.

Install a new seal ring to the output shaft spacer.

Align the pin with the straight pin groove of the output shaft spacer, and slide on the output shaft spacer.

Using a screwdriver and hammer, tap on the snap ring.

Install the 2 output shaft washers to the output shaft.

Using SST and a hammer, tap in a new input shaft plug until its surface is 1.0 to 1.8 mm (0.0394 to 0.0709 in.) from the input shaft upper surface.

• SST
• 09950-60010(09951-00410)
  09950-70010(09951-07150)

• NOTICE:

• Be careful not to damage or deform the input shaft plug when tapping it.

Using SST and a hammer, tap in a new bush until its surface is 5.5 to 5.9 mm (0.217 to 0.232 in.) from the input shaft upper surface.

• SST
• 09950-70010(09951-07150)
  09950-60010(09951-00610)

• NOTICE:

• Be careful not to damage the input shaft.

Install the low planetary gear bearing and low planetary gear to the input shaft.

• NOTICE:

Install the low planetary gear bearing and a new input shaft bearing to the input shaft.

• NOTICE:

Using SST and a press, press in the bearing.

• SST
• 09513-36040
  09515-21010

• NOTICE:

• After press-fitting the bearing to the input shaft, check that the bearing moves smoothly.

Select a snap ring that allows for minimum axial play and install it to the shaft.

• Standard Snap Ring Thickness:

• Mark	Specified Condition
  C	2.13 to 2.18 mm (0.0839 to 0.0858 in.)
  D	2.18 to 2.23 mm (0.0858 to 0.0878 in.)
  E	2.23 to 2.28 mm (0.0878 to 0.0898 in.)
  F	2.28 to 2.33 mm (0.0898 to 0.0917 in.)
  G	2.33 to 2.38 mm (0.0917 to 0.0937 in.)
  H	2.38 to 2.43 mm (0.0937 to 0.0957 in.)
  J	2.43 to 2.48 mm (0.0957 to 0.0976 in.)

Using a snap ring expander, install the snap ring.

• NOTICE:

• Make sure that the snap ring is firmly installed to the groove.

Apply transfer oil to a new seal ring.

Install a new seal ring to the input shaft.

Install a new bearing to the front transfer case in the direction shown in the illustration.

• NOTICE:

• Make sure the bearing is installed in the correct direction.

Using a screwdriver, install the snap ring.

Using a snap ring expander, install the snap ring to the front transfer case.

Install the low planetary ring gear to the front transfer case.

• NOTICE:

• Make sure to install the low planetary ring gear in the correct direction.

Using a screwdriver, install the snap ring.

• NOTICE:

• Make sure that the snap ring is firmly installed to the groove.

While expanding the snap ring, install the input shaft to the front transfer case.

Apply adhesive to the threads of the 2 case plugs.

• Adhesive:
• Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

• NOTICE:

• Install the plugs within 3 minutes of application.

Using a 14 mm hexagon wrench, install the 2 case plugs.

• Torque:
• 37 N*m{ 377 kgf*cm, 27 ft.*lbf}

Install the magnet to the oil separator.

Install a new O-ring to the oil separator.

Install the oil separator with the 3 bolts.

• Torque:
• 18 N*m{ 178 kgf*cm, 13 ft.*lbf}

Using SST and a hammer, tap in a new bearing to the rear transfer case.

• SST
• 09950-60010(09951-00590)
  09950-70010(09951-07100)

Using a screwdriver, install the snap ring.

Apply gear oil to the connecting areas of the clutch sleeve and center differential case.

Install the clutch sleeve onto the output shaft.

• NOTICE:

• Make sure that the clutch sleeve is installed facing the correct direction.

Install the snap ring to the rear transfer case.

Install the output shaft, drive chain and driven sprocket.

• NOTICE:

• Do not drop the output shaft washers.

Using a snap ring expander, install the snap ring to the output shaft.

• NOTICE:

• Make sure that the snap ring is firmly installed to the groove.

Install a new O-ring to the shift actuator.

Set the No. 1 gear shift fork to the front drive clutch sleeve.

Install the shift actuator to the rear transfer case with the 3 bolts.

• Torque:
• 20 N*m{ 204 kgf*cm, 15 ft.*lbf}

Install the No. 1 gear shift fork to the shift actuator with the bolt.

• Torque:
• 24 N*m{ 245 kgf*cm, 18 ft.*lbf}

Set the No. 2 gear shift fork together with the high and low clutch sleeve to the shift actuator.

Install the No. 2 gear shift fork to the shift actuator with the bolt.

• Torque:
• 24 N*m{ 245 kgf*cm, 18 ft.*lbf}

Using a screwdriver and hammer, tap the 4 shift fork shaft snap rings onto the shift fork shaft.

Install the needle roller bearing and spacer to the output shaft.

Align the protrusion of the synchronizer ring with the notch on the differential case and install it.

Apply seal packing to the rear transfer case as shown in the illustration.

• Seal Packing:
• Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

• NOTICE:

• If the removed rear transfer case will be reused: After removing the rear transfer case, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old FIPG on the rear transfer case contact surface, 2) clean off any remaining old FIPG from the rear transfer case contact surface, and 3) reapply seal packing to the rear transfer case.

Install the rear transfer case with the 14 bolts.

• Torque:
• 28 N*m{ 286 kgf*cm, 21 ft.*lbf}

• NOTICE:

• Tighten the bolts within 10 minutes of applying the seal packing. The seal packing will dry very quickly.

Apply adhesive to the threads of the plug.

• Adhesive:
• Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

• NOTICE:

• Install the plug within 3 minutes of application.

Using a 6 mm hexagon wrench, install the plug.

• Torque:
• 39 N*m{ 400 kgf*cm, 29 ft.*lbf}

Install the pin and compression spring to the front transfer case.

Apply adhesive to the threads of the plug.

• Adhesive:
• Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

• NOTICE:

• Install the plug within 3 minutes of application.

Install the plug.

• Torque:
• 19 N*m{ 190 kgf*cm, 14 ft.*lbf}

Apply transfer oil to the spline of the output shaft.

Using SST and a hammer, tap in a new oil seal until its surface is flush with the housing upper surface.

• SST
• 09649-17010
  09950-70010(09951-07150)

Install the companion flange onto the output shaft.

Using SST to hold the companion flange, install a new O-ring and a new companion flange lock nut.

• SST
• 09330-00021

• Torque:
• 127 N*m{ 1299 kgf*cm, 94 ft.*lbf}

Using a chisel and hammer, stake the companion flange lock nut.

Apply transfer oil to the spline of the driven sprocket.

Using SST and a hammer, tap in a new front transfer case oil seal.

• SST
• 09613-26010

• NOTICE:

• The front transfer case oil seal should be installed completely.

Using SST and a press, install a new transfer output shaft dust deflector.

• SST
• 09523-36010
  09950-60010(09951-00460,09951-00560,09952-06010)
  09950-70010(09951-07100)

• NOTICE:

Apply MP grease to the transfer output shaft dust deflector lip.

• Standard Grease Capacity:
• Location A:
• 0.4 to 0.6 g (0.015 to 0.021 oz.)
• Location B:
• 0.1 g (0.0004 oz.)

Install the companion flange onto the drive sprocket.

Using SST to hold the companion flange, install a new O-ring and a new companion flange lock nut.

• SST
• 09330-00021

• Torque:
• 127 N*m{ 1299 kgf*cm, 94 ft.*lbf}

Using a chisel and hammer, stake the companion flange lock nut.

Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump plate upper surface.

• SST
• 09950-60020(09951-00680)
  09950-70010(09951-07100)

• NOTICE:

• Be careful not to damage the oil pump plate.

Install the relief valve seat, ball and compression spring to the oil pump plate.

Apply adhesive to the threads of the plug.

• Adhesive:
• Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

• NOTICE:

• Install the plug within 3 minutes of application.

Using a 10 mm hexagon wrench, install the plug.

• Torque:
• 29 N*m{ 300 kgf*cm, 22 ft.*lbf}

Install the 2 straight pins to the input shaft.

Apply transfer oil to a new O-ring, drive rotor, driven rotor and a new transfer oil seal ring.

Install the drive rotor to the input shaft.

Install the transfer oil seal ring to the input shaft.

Install the O-ring to the oil pump plate.

Install the oil pump plate and driven rotor to the front transfer case with the 4 bolts.

• Torque:
• 12 N*m{ 117 kgf*cm, 9 ft.*lbf}

Install the bracket to the rear transfer case with the bolt.

• Torque:
• 20 N*m{ 204 kgf*cm, 15 ft.*lbf}