Transfer Assembly Reassembly

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

Using a screwdriver, install the snap ring.

Install the pin.

Install the spring.

Install the transfer case plug.

Torque:

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

Install the washer.

Install the bearing.

Install the transfer drive sprocket.

Install the output shaft spacer.

Using SST and a press, install a new bearing.

SST

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

Text in Illustration

*1	Groove
	Rear

NOTICE:

Install the bearing so that the bearing snap ring groove faces the rear.

Install the washer.

Install the needle roller bearing.

Install the transfer clutch hub.

Install the center differential case.

Install the ball.

Install the spacer.

Using a snap ring expander, install the snap ring.

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

Standard clearance:

0.01 to 0.06 mm (0.000394 to 0.0236 in.)

Maximum clearance:

0.06 mm (0.0236 in.)

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

Standard clearance:

0.15 to 0.24 mm (0.00591 to 0.00944 in.)

Maximum clearance:

0.24 mm (0.00944 in.)

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

SST

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

Select a new snap ring that allows minimal axial play.

Standard Snap Ring Thickness:

Mark	Specified Condition
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.)

Using a snap ring expander, install the snap ring.

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

Using SST and a press, press in a new low planetary gear bearing.

SST

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

Press in depth:

7.7 to 8.3 mm (0.304 to 0.326 in.)

Apply gear oil to 2 new seal rings.

Install the 2 seal rings to the input shaft.

NOTICE:

When installing the seal ring, make sure not to expand it so that its inner diameter exceeds 65 mm (2.55 in.).

Install the bearing.

Text in Illustration

Front

Install the thrust bearing race.

Install the transfer input shaft.

Install the washer.

Install the ball.

Install the input gear stopper.

Select a new input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.00197 to 0.00590 in.) of axial play.

Standard Snap Ring Thickness:

Specified Condition

2.10 to 2.15 mm (0.0827 to 0.0846 in.)

2.15 to 2.20 mm (0.0846 to 0.0866 in.)

2.20 to 2.25 mm (0.0866 to 0.0886 in.)

2.25 to 2.30 mm (0.0886 to 0.0906 in.)

2.30 to 2.35 mm (0.0906 to 0.0925 in.)

2.35 to 2.40 mm (0.0925 to 0.0945 in.)

2.40 to 2.45 mm (0.0945 to 0.0965 in.)

2.45 to 2.50 mm (0.0965 to 0.0984 in.)

2.50 to 2.55 mm (0.0984 to 0.100 in.)

2.55 to 2.60 mm (0.100 to 0.102 in.)

2.60 to 2.65 mm (0.102 to 0.104 in.)

2.65 to 2.70 mm (0.104 to 0.106 in.)

2.70 to 2.75 mm (0.106 to 0.108 in.)

2.75 to 2.80 mm (0.108 to 0.110 in.)

2.80 to 2.85 mm (0.110 to 0.112 in.)

2.85 to 2.90 mm (0.112 to 0.114 in.)

2.90 to 2.95 mm (0.114 to 0.116 in.)

2.95 to 3.00 mm (0.116 to 0.118 in.)

3.00 to 3.05 mm (0.118 to 0.120 in.)

Using a snap ring expander, install the snap ring.

Install the low planetary gear together with the input shaft.

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

Install the transfer oil pump gear.

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

Install the oil 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.

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}

Install a new O-ring to the transfer shift actuator assembly.

Install the transfer shift actuator assembly with the 3 bolts.

Torque:

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

Using a screwdriver and hammer, tap on the 2 snap rings.

Using SST and a press, install a new input gear radial ball bearing.

SST

09316-60011(09316-00031)

Using SST and a press, install a new driven sprocket bearing.

SST

09316-60011(09316-00071)

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

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

HINT:

Check that the rear output shaft and driven sprocket turn without much effort.

Using a snap ring expander, install the snap ring.

NOTICE:

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

Install the center differential lock fork and front drive clutch sleeve.

Text in Illustration

Front

NOTICE:

Install the clutch sleeve in the correct direction.

Install the bolt.

Torque:

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

Using a screwdriver and hammer, drive in the snap ring.

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

Text in Illustration

Front

NOTICE:

Install the clutch sleeve in the correct direction.

Install the bolt.

Torque:

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

Install the needle roller bearing to the input shaft.

Install the transfer output shaft spacer to the input shaft.

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

Install the clamp and rear transfer case with the 12 bolts.

Torque:

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

NOTICE:

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

Install the collar.

Install the 2 washers.

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 is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the housing contact surface, 2) clean off any remaining old seal packing from the housing contact surface, and 3) reapply seal packing to the housing.

Apply adhesive to the threads of the bolts.

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.

Coat the lip of a new oil seal with MP grease.

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

SST

09223-46011
09631-32020

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

SST

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

Coat the lip of the oil seal with MP grease.

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

Install the companion flange to the output shaft.

Text in Illustration

Rear

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

SST

09330-00021

Torque:

118 N*m{1203 kgf*cm, 87 ft.*lbf}

Using a chisel and hammer, stake the lock nut.

NOTICE:

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

Coat the lip of a new oil seal with MP grease.

Using SST and a hammer, tap in the oil seal until its metal ring contacts the case.

SST

09649-17010
09950-70010(09951-07100)

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

SST

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

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.

Text in Illustration

Front

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

SST

09330-00021

Torque:

118 N*m{1203 kgf*cm, 87 ft.*lbf}

Using a chisel and hammer, stake the lock nut.

NOTICE:

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

Install the oil deflector.

Install the case cover with the 4 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

for A750F, AC60F, G52F, R150F:
Using SST and a hammer, drive in a new transfer bearing retainer oil seal RH until its surface is flush with the retainer upper surface.

SST

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

for RA61F:
Using SST and a hammer, tap in 2 new transfer bearing retainer oil seals RH A and B as shown in the illustration.

SST

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

1. for oil seal A:
   

   Drive in depth (A):

   43 to 44 mm (1.70 to 1.73 in.)
   

   Text in Illustration

   *1	Oil Seal A





2. for oil seal B:
   

   Drive in depth (B):

   53.5 to 54 mm (2.11 to 2.12 in.)
   

   Text in Illustration

   *1	Oil Seal B

Coat the lip of the transfer bearing retainer oil seal RH with MP grease.

for RA61F:
Install a new O-ring to the transfer bearing retainer sub-assembly RH.

NOTICE:

Apply MP grease to the O-ring when installing the transfer onto the transmission.

Apply seal packing to the transfer bearing retainer sub-assembly RH as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

If the removed transfer bearing retainer sub-assembly RH is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the retainer contact surface, 2) clean off any remaining old seal packing from the retainer contact surface, and 3) reapply seal packing to the transfer bearing retainer sub-assembly RH.

Apply sealant to the bolt threads.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the transfer bearing retainer sub-assembly RH with the 5 bolts.

Torque:

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

NOTICE:

Tighten the bolts of the transfer bearing retainer sub-assembly RH within 10 minutes of applying the seal packing. The seal packing will dry very quickly.

Attach the clamp and install the hose.