Transfer Assembly Reassembly

Install the ring gear to the front case.

NOTICE:

Make sure to install the 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.

Apply adhesive to the threads of the plug.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the case plug.

Torque:

18.6 N*m{190 kgf*cm, 14 ft.*lbf}

Apply gear oil to the connecting areas of the output shaft and bearing.

Using SST and a press, press in a new bearing with the outer race snap ring groove toward the rear.

SST

09316-60011(09316-00011,09316-00071)

Using a snap ring expander, install the snap ring.

NOTICE:

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

Using a dial indicator, measure the radial clearance of the drive sprocket.

Standard clearance:

0.01 to 0.06 mm (0.0004 to 0.0024 in.)

Maximum clearance:

0.06 mm (0.0024 in.)

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

Standard clearance:

0.15 to 0.24 mm (0.0059 to 0.0094 in.)

Maximum clearance:

0.24 mm (0.0094 in.)

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

SST

09950-60010(09951-00570)
09950-70010(09951-07100)

Standard depth:

7.7 to 8.3 mm (0.303 to 0.327 in.)

Using SST and a press, press in a new bearing with the groove facing forward.

SST

09223-15020
09515-30010
09950-70010(09951-07100)

Using a screwdriver, install the spline piece and low planetary gear with the snap ring.

NOTICE:

1. Be careful not to damage the spline piece.
   
2. Make sure that the snap ring is firmly installed to the groove.
   

Select a new snap ring that allows 0.1 mm (0.0039 in.) or less of axial free play.

Standard snap ring thickness:

Mark	Thickness
1	1.45 to 1.50 mm (0.0571 to 0.0591 in.)
2	1.50 to 1.55 mm (0.0591 to 0.0610 in.)
3	1.55 to 1.60 mm (0.0610 to 0.0630 in.)
4	1.60 to 1.65 mm (0.0630 to 0.0650 in.)
5	1.65 to 1.70 mm (0.0650 to 0.0669 in.)

NOTICE:

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

Using a snap ring expander, install the snap ring.

Apply gear oil to the 2 seal rings.

Install the 2 seal rings to the input shaft.

HINT:

Engage the seal rings securely to eliminate clearance as shown in the illustration.

Install the bearing to the low planetary gear.

NOTICE:

Make sure to install the bearing in the correct direction.

Apply gear oil to the contact surface of the input shaft and low planetary gear.

Install the input shaft to the low planetary gear.

Apply gear oil to the washer.

Install the washer to the low planetary gear.

Select a new snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) of axial free play.

Standard snap ring thickness:

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

Using a snap ring expander, install the snap ring.

NOTICE:

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

Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 1).

SST

09316-60011(09316-00011)

NOTICE:

Be careful not to damage the front case.

Coat the lip of the oil seal with MP grease.

Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 2).

SST

09304-12012

Standard depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

NOTICE:

Be careful not to damage the front case.

Coat the lip of the oil seal with MP grease.

Install the low planetary gear with input shaft.

HINT:

If necessary, heat the front case to about 50 to 80°C (122 to 176°F).

Using a snap ring expander, install the snap ring.

NOTICE:

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

Apply gear oil to the sliding surface of the gear.

Install the gear with the nut.

Coat a new O-ring with gear oil and install it to the oil pump body.

Install the pump body with the 3 bolts.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}

Install the oil separator with the 3 bolts.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}

Install a new gasket and the filler plug (for filler).

Torque:

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

Install a new gasket and the drain plug.

Torque:

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

Apply gear oil to the contact surface of the bearing and driven sprocket.

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

SST

09316-60011(09316-00031)

NOTICE:

After press-fitting the bearing to the driven sprocket, check that the bearing moves smoothly.

Apply gear oil to the contact surfaces of the bearing and driven sprocket.

Using a press, press in a new bearing.

NOTICE:

After press-fitting the bearing to the driven sprocket, check that the bearing moves smoothly.

Install the output shaft and driven sprocket to the front drive chain.

Mount the rear case in a vise.

NOTICE:

Place aluminum plates on the vise to prevent damage to the rear case.

Install the output shaft, front drive chain and driven sprocket to the rear case.

HINT:

Check that the output shaft and driven sprocket turn smoothly. If necessary, heat the rear case to about 50 to 80°C (122 to 176°F).

Using a snap ring expander, install the snap ring.

NOTICE:

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

Install the clutch sleeve.

NOTICE:

Make sure to install the clutch sleeve in the correct direction.

Install the front drive shift shaft, center differential lock fork, shift shaft stopper, 2 springs and 3 stoppers.

Install the ball and spring to the hole.

Apply adhesive to the threads of the No. 2 plug.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the No. 2 plug to the hole.

Torque:

18.6 N*m{190 kgf*cm, 14 ft.*lbf}

Using a pin punch and hammer, tap in the slotted pin.

NOTICE:

When installing the slotted pin, make sure the pin's groove (labeled A) is facing in the same direction as the shaft.

Manual transmission:
Install the synchronizer ring, 3 shifting keys and 2 springs.

NOTICE:

1. Set the No. 1 springs so that their openings do not overlap, as shown in the illustration.
   
2. Make sure that the No. 1 springs are firmly connected to the shifting keys.
   

Install the straight pin to the hole.

Install the No. 2 gear shift fork, high and low shift fork shaft and high and low clutch sleeve.

NOTICE:

Make sure to install the fork in the correct direction.

Install the ball and spring to the hole.

Apply adhesive to the threads of the No. 1 plug.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the No. 1 plug to the hole.

Using a pin punch and hammer, install the slotted pin.

NOTICE:

When installing the slotted pin, make sure the pin's groove (labeled A) is facing in the same direction as the shaft.

Apply gear oil to the bearing.

Install the bearing to the low planetary gear.

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

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

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

Install the 2 clamps and rear case with the 12 bolts.

Torque:

28 N*m{285 kgf*cm, 21 ft.*lbf}

NOTICE:

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

Install the speedometer drive gear and 2 output washers.

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

SST

09223-46011
09631-32020

NOTICE:

Be careful not to damage the extension housing.

Coat the lip of the oil seal with MP grease.

Apply seal packing to the extension housing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

If the removed extension housing will be reused: After removing the housing, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the extension housing's contact surface, 2) clean off any remaining old seal packing from the extension housing's contact surface, and 3) apply seal packing to the extension housing.

Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the extension housing with the 5 bolts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

NOTICE:

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

Install the sensor with driven gear with the bolt.

Torque:

11.5 N*m{117 kgf*cm, 8 ft.*lbf}

Connect the sensor connector.

Using SST and a hammer, tap in a new oil seal (for front).

SST

09950-60010(09951-00320)
09950-70010(09951-07100)

NOTICE:

Be careful not to damage the companion flange.

Coat the lip of the oil seal with MP grease.

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

SST

09950-60010(09951-00320)
09950-70010(09951-07100)

NOTICE:

Be careful not to damage the companion flange.

Coat the lip of the oil seal with MP grease.

Apply gear oil to the connecting areas of the companion flange and driven sprocket.

Install the companion flange to the driven sprocket.

Using SST to hold the companion flange, install a new lock nut.

SST

09330-00021
09950-40011(09951-04020,09952-04010,09953-04030,09955-04051,09957-04010,09958-04011)

Torque:

118 N*m{1,203 kgf*cm, 87 ft.*lbf}

Using a chisel and hammer, stake the lock nut to the driven sprocket.

NOTICE:

1. Thoroughly stake the shaft to the lock nut's groove.
   
2. Be careful not to damage parts around the lock nut.
   
3. Do not apply excessive force to the shaft.
   

Apply gear oil to the connecting area of the companion flange and output shaft.

Install the companion flange to the output shaft.

Using SST to hold the companion flange, install a new lock nut.

SST

09330-00021
09950-40011(09951-04020,09952-04010,09953-04030,09954-04010,09955-04051,09957-04010,09958-04011)

Torque:

118 N*m{1,203 kgf*cm, 87 ft.*lbf}

Install the retainer with the 4 bolts.

Torque:

18 N*m{183 kgf*cm, 13 ft.*lbf}

Install the case cover with the 4 bolts.

Torque:

18 N*m{183 kgf*cm, 13 ft.*lbf}

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

SST

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

NOTICE:

Be careful not to damage the bearing retainer.

Apply seal packing to the bearing retainer as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

If the removed bearing retainer will be reused: After removing the retainer, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the bearing retainer's contact surface, 2) clean off any remaining old seal packing from the bearing retainer's contact surface, and 3) apply seal packing to the bearing retainer.

Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the bearing retainer with the 5 bolts.

Torque:

11.5 N*m{117 kgf*cm, 8 ft.*lbf}

NOTICE:

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

Install the No. 1 and No. 2 gear shift heads to the front drive shift fork shaft and high and low shift fork shaft.

Using a pin punch and hammer, tap in the 2 slotted pins to the No. 1 and No. 2 gear shift heads.

NOTICE:

When installing the slotted pins, make sure the pin's groove (labeled A) is facing in the same direction as the shaft.

Install new gaskets and the indicator switches.

Torque:

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

HINT:

Indicator switch: