1. REMOVE ENGINE UNDER COVER SUB-ASSY NO. 1 (See ...ww2.justanswer.com/...232634_2005_toyota_4runner-4.pdf · 11/15/2011 · Fig. 18: Removing Bolts And Case Cover Sub-Assy Courtesy

OVERHAUL

REMOVE ENGINE UNDER COVER SUB-ASSY NO. 1 (See REPLACEMENT )1.

REMOVE ENGINE UNDER COVER ASSY REAR (See REPLACEMENT )2.

DISCONNECT OXYGEN SENSOR (See REPLACEMENT )3.

REMOVE EXHAUST PIPE ASSY (1GR-FE)4.

REMOVE PROPELLER SHAFT ASSY FRONT (See OVERHAUL )5.

REMOVE PROPELLER SHAFT ASSY (See OVERHAUL )6.

DRAIN AUTOMATIC TRANSMISSION FLUID (See REPLACEMENT )7.

DRAIN TRANSFER OIL8.

REMOVE FRONT SUSPENSION MEMBER BRACKET (See REPLACEMENT )9.

REMOVE FRONT SUSPENSION MEMBER BRACKET LH (See REPLACEMENT )10.

REMOVE TRANSMISSION OIL FILTER TUBE SUB-ASSY (See REPLACEMENT )11.

DISCONNECT OIL COOLER OUTLET TUBE NO. 1 (See REPLACEMENT )12.

SST 09023-12701

REMOVE OIL COOLER INLET TUBE NO. 1 (See REPLACEMENT )13.

SST 09023-12701

DISCONNECT TRANSMISSION CONTROL CABLE ASSY (See REPLACEMENT )14.

REMOVE TRANSMISSION CONTROL CABLE BRACKET NO. 1 (SeeREPLACEMENT )

15.

REMOVE TRANSFER CASE LOWER PROTECTOR16.

Remove the 4 bolts and transfer case lower protector.a.

Page 1 of 114TRANSFER CASE -2005 Toyota 4Runner SR5

11/15/2011http://www.ondemand5.com/mric/common/asp/printart.aspx

Fig. 15: Removing Bolts And Transfer Case Lower ProtectorCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SUPPORT AUTOMATIC TRANSMISSION W/TRANSFER (See REPLACEMENT )17.

REMOVE FRAME CROSSMEMBER SUB-ASSY NO. 3 (See REPLACEMENT )18.

DISCONNECT CONNECTOR (See REPLACEMENT )19.

DISCONNECT WIRE HARNESS (See REPLACEMENT )20.

REMOVE STARTER ASSY (See REPLACEMENT )21.

REMOVE MANIFOLD STAY (See REPLACEMENT )22.

REMOVE MANIFOLD STAY NO. 2 (See REPLACEMENT )23.

SEPARATE FRONT DIFFERENTIAL ASSY (See REPLACEMENT )24.

REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (See REPLACEMENT )25.

REMOVE TRANSFER ASSY26.

Remove the 8 bolts and 2 clamps.a.

Remove the transfer from the automatic transmission.b.



Fig. 16: Removing Bolts And ClampsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE HOSE27.

REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY28.

Remove the 5 bolts and front bearing retainer sub-assy.a.

HINT:

If necessary, tap the front bearing retainer sub-assy with a plastic hammer to remove it.



Fig. 17: Removing Bolts And Front Bearing Retainer Sub-AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER COVER TYPE T OIL SEAL29.

Using a screwdriver and hammer, remove the oil seal from the front bearing retainer sub-assy.

a.

REMOVE TRANSFER CASE COVER SUB-ASSY30.

Remove the 4 bolts and case cover sub-assy.a.

REMOVE BREATHER OIL DEFLECTOR31.



Fig. 18: Removing Bolts And Case Cover Sub-AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSY32.

Using a chisel and hammer, loosen the staked part of the output shaft companion flangelock nut.

a.

Using SST to hold the output shaft companion flange, remove the output shaft companionflange lock nut.

b.

SST 09330-00021



Fig. 19: Holding Output Shaft Companion Flange, Using SSTCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Using SST, remove the output shaft companion flange sub-assy.c.

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



Fig. 20: Removing Output Shaft Companion Flange Sub-Assy, Using SSTCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL33.

Using a screwdriver and hammer, remove the oil seal from the output shaft companionflange sub-assy.

a.

REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSY34.

Remove the rear output shaft companion flange sub-assy in the same way as the frontoutput shaft companion flange sub-assy.

a.

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

REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL35.

Using a screwdriver and hammer, remove the oil seal from the rear output shaftcompanion flange sub-assy.

a.

REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY FRONT36.

Remove the 5 bolts and extension housing sub-assy rear.a.



HINT:

If necessary, tap the extension housing sub-assy rear with a plastic hammer to remove it.

REMOVE OIL (TRANSFER EXTENSION FRONT HOUSING SUB-ASSY) SEAL37.

Using a screwdriver and hammer, remove the oil seal.a.

Fig. 21: Removing Bolts And Extension Housing Sub-Assy RearCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER OUTPUT WASHER38.

REMOVE COLLAR39.



Fig. 22: Removing Transfer Output WasherCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER CASE REAR40.

Remove the 12 bolts and clamp.a.

Remove the transfer case rear.b.

HINT:

If necessary, tap the transfer case rear with a plastic hammer to remove it.



Fig. 23: Removing Bolts And ClampCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER GEAR SHIFT FORK NO. 2 W/TRANSFER HIGH AND LOWCLUTCH SLEEVE

41.

Remove the bolt, gear shift fork No. 2 and high and low clutch sleeve.a.



Fig. 24: Removing Bolt, Gear Shift Fork No. 2 And High And Low Clutch SleeveCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER SHIFT SHAFT STOPPER42.

Remove the bolt and shift shaft stopper.a.

REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT43.

Turn the front drive shift fork shaft, and remove it from the rear case aligning the cut outposition and the inter-lock pin position.

a.



Fig. 25: Removing Front Drive Shift Fork ShaftCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE OR ROLLER SHIFT INTER-LOCK PIN44.

Using a magnetic finger, remove the 2 shift inter-lock pin.a.

REMOVE NO. 2 STOPPER TRANSFER SHIFT SHAFT45.



Fig. 26: Removing Shift Inter-Lock PinCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE REAR OUTPUT SHAFT SUB-ASSY, GEAR SHIFT FORK NO. 1, FRONTDRIVE CLUTCH SLEEVE, FRONT DRIVE CHAIN AND DRIVEN SPROCKET

46.

Using 2 screwdrivers and a hammer, tap out the snap ring.a.



Fig. 27: Using Screwdrivers And Hammer, Tap Out Snap RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Using 2 screwdrivers and a hammer, tap out the snap ring.b.




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



Fig. 29: Removing Snap RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Mount the transfer case rear in a vise.d.

Using a plastic hammer, carefully tap the transfer case rear, and remove the rear outputshaft sub-assy together with gear shift fork No. 1, front drive clutch sleeve, front drivechain and driven sprocket sub-assy.

e.



Fig. 30: Removing Front Drive Chain And Driven Sprocket Sub-AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the rear output shaft sub-assy, gear shift fork No. 1, front drive chain and drivensprocket sub-assy.

f.



Fig. 31: Removing Rear Output Shaft Sub-Assy, Front Drive Chain And DrivenSprocket Sub-AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE NO. 2 STOPPER TRANSFER SHIFT SHAFT47.



Fig. 32: Removing No. 2 Stopper Transfer Shift ShaftCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER DRIVEN SPROCKET BEARING48.

Using a press, remove the driven sprocket bearing.a.



Fig. 33: Removing Driven Sprocket Bearing, Using PressCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING49.

Using SST, a press and steel bar, remove the transfer input gear radial ball bearing.a.

SST 09555-55010



Fig. 34: Removing Transfer Input Gear Radial Ball BearingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER SHIFT ACTUATOR ASSY50.

Using 2 screwdrivers and a hammer, tap out the snap ring.a.




Remove the 3 bolts and transfer shift actuator assy.b.

REMOVE TRANSFER CASE NO. 1 PLUG51.

Remove the transfer case No. 1 plug (filler plug) and gasket.a.

REMOVE TRANSFER CASE NO. 1 PLUG52.

Remove the transfer case No. 1 plug (drain plug) and gasket.a.



Fig. 36: Removing Bolts And Transfer Shift Actuator AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER OIL SEPARATOR SUB-ASSY53.

Remove the 3 bolts and oil separator sub-assy.a.

REMOVE TRANSFER CASE MAGNET54.



Fig. 37: Removing Bolts And Oil Separator Sub-AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER OIL PUMP BODY SUB-ASSY55.

Remove the 3 bolts and oil pump body sub-assy.a.



Fig. 38: Removing Bolts And Oil Pump Body Sub-AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER OIL PUMP BODY O-RING56.

Using a screwdriver, remove the oil pump body O-ring.a.



Fig. 39: Removing Oil Pump Body O-Ring, Using ScrewdriverCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER OIL PUMP GEAR57.



Fig. 40: Removing Transfer Oil Pump GearCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE LOW PLANETARY GEAR ASSY W/INPUT SHAFT SUB-ASSY58.

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




Remove the low planetary gear assy and input shaft sub-assy.b.



Fig. 42: Removing Low Planetary Gear Assy And Input Shaft Sub-AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER OUTPUT SHAFT SPACER59.

REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING60.

REMOVE TRANSFER CASE OIL SEAL61.

Using a screwdriver and hammer, remove the transfer case oil seal.a.



Fig. 43: Removing Transfer Case Oil SealCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING62.

Using a snap ring expander, remove the input gear stopper shaft snap ring.a.



Fig. 44: Removing Input Gear Stopper Shaft Snap RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER INPUT GEAR STOPPER63.

REMOVE TRANSFER INPUT GEAR STOPPER BALL64.

REMOVE MANUAL TRANSFER PLANETARY CARR WASHER65.



Fig. 45: Removing Manual Transfer Planetary Carr WasherCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE SHAFT, TRANSFER INPUT66.

REMOVE TRANSFER THRUST BEARING RACE NO. 167.

REMOVE TRANSFER LOW PLANETARY GEAR BEARING68.



Fig. 46: Removing Transfer Low Planetary Gear BearingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER INPUT SHAFT SEAL RING NO. 169.







Fig. 47: Removing Transfer Input Shaft Seal Ring No. 1Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECT SHAFT, TRANSFER INPUT70.

Using a micrometer, measure the outer diameter of the input shaft journal surface.a.

Minimum diameter: 47.59 mm (1.8736 in.)

If the outer diameter is less than the minimum, replace the input shaft.



Fig. 48: Measuring Outer Diameter Of Input Shaft Journal SurfaceCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Using a dial indicator, measure the inside diameter of the input shaft bushing.b.

Maximum diameter: 48.14 mm (1.8953 in.)

If the inside diameter exceeds the maximum, replace the input shaft.



Fig. 49: Measuring Inside Diameter Of Input Shaft BushingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECT PLANETARY PINION GEAR THRUST CLEARANCE71.

Using a feeler gauge, measure the thrust clearance of the planetary pinion gear.a.

Standard clearance:

0.11 - 0.84 mm (0.0043 - 0.0331 in.)



Maximum clearance:

0.84 mm (0.0331 in.)

If the clearance exceeds the maximum, replace the planetary gear assy.

Fig. 50: Measuring Thrust Clearance Of Planetary Pinion GearCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE72.

Using a dial indicator, measure the radial clearance of the planetary pinion gear.a.

Standard clearance:

0.009 - 0.038 mm (0.0004 - 0.0015 in.)



Maximum clearance:

0.038 mm (0.0015 in.)

If the clearance exceeds the maximum, replace the planetary gear assy.

Fig. 51: Measuring Radial Clearance Of Planetary Pinion GearCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER INPUT SHAFT BEARING73.


Using SST and a press, remove the input shaft bearing.b.

SST 09554-30011, 09555-55010



Fig. 52: Removing Input Shaft Bearing, Using SST And PressCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE74.

Using a screwdriver, remove the snap ring.a.

Remove the low planetary gear spline piece.b.



Fig. 53: Removing Snap Ring, Using ScrewdriverCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER LOW PLANETARY GEAR BEARING75.

Using SST, remove the low planetary gear bearing.a.

NOTE: Hang SST securely to the clearance between the bearing and lowplanetary gear.

SST 09612-65014 (09612-01030, 09612-01050)



Fig. 54: Removing Low Planetary Gear Bearing, Using SSTCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECT DRIVE SPROCKET THRUST CLEARANCE76.

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

Standard clearance:

0.15-0.24 mm (0.0059 - 0.0094 in.)

Maximum clearance:

0.24 mm (0.0094 in.)

If the clearance exceeds the maximum, replace the drive sprocket.



Fig. 55: Measuring Thrust Clearance Of Drive SprocketCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECT DRIVE SPROCKET RADIAL CLEARANCE77.

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

Standard clearance:

0.01 - 0.06 mm (0.0004 - 0.0024 in.)

Maximum clearance: 0.06 mm (0.0024 in.)

If the clearance exceeds the maximum, replace the drive sprocket, output shaft rear or needleroller bearing.



Fig. 56: Measuring Radial Clearance Of Drive SprocketCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING78.


REMOVE TRANSFER OUTPUT SHAFT SPACER NO. 279.

REMOVE TRANSFER OUTPUT SHAFT SPACER BALL80.

REMOVE CENTER DIFFERENTIAL CASE81.




REMOVE TRANSFER CLUTCH HUB82.

REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING83.

REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER84.



Fig. 58: Removing Transfer Output Shaft Plate WasherCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER SYNCHROMESH SHIFTING KEY SPRING85.

Using a screwdriver, remove the 2 shifting key springs.a.

REMOVE SYNCHROMESH SHIFTING KEY TRANSFER DRIVE86.

Remove the 3 shifting keys.a.

REMOVE FRONT DRIVE CLUTCH SLEEVE87.



Fig. 59: Removing Shifting Key SpringsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER SYNCHRONIZER RING SET88.



Fig. 60: Removing Transfer Synchronizer Ring SetCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING89.

Using SST and a press, remove the output shaft rear radial ball bearing.a.

SST 09555-55010



Fig. 61: Removing Output Shaft Rear Radial Ball Bearing, Using SST And PressCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER OUTPUT SHAFT SPACER NO. 190.

REMOVE TRANSFER DRIVE SPROCKET SUB-ASSY91.

REMOVE TRANSFER DRIVE SPROCKET BEARING92.

REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER93.



Fig. 62: Removing Transfer Output Shaft Plate WasherCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECT TRANSFER OUTPUT SHAFT REAR94.

Using a micrometer, measure the outer diameter of the output shaft rear journal surface.a.

Standard diameter:

Part A: 27.98 - 27.99 mm (1.1016 - 1.1020 in.)

Part B: 31.98 - 32.00 mm (1.2591 - 1.2598 in.)

Part C: 34.98 - 35.00 mm (1.3772 - 1.3780 in.)

Part D: 36.98 - 37.00 mm (1.4559 - 1.4567 in.)

Minimum diameter:



Part A: 27.98 mm (1.1016 in.)

Part B: 31.98 mm (1.2591 in.)

Part C: 34.98 mm (1.3772 in.)

Part D: 36.98 mm (1.4559 in.)

Fig. 63: Measuring Outer Diameter Of Output Shaft Rear Journal SurfaceCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

If the outer diameter is less than the minimum, replace the output shaft rear.

INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO. 2CLEARANCE

95.

Using vernier calipers, measure the thickness of the gear shift fork No. 2 claw.a.

Thickness: 10 mm (0.3937 in.)

Using vernier calipers, measure the groove of the high and low clutch sleeve.b.

Distance: 10.5 mm (0.4134 in.)



Calculate a clearance between the high and low clutch sleeve and gear shift fork No. 2clearance.

c.

Standard clearance:

0.26 - 0.84 mm (0.0102 - 0.0331 in)

Maximum clearance:

0.84 mm (0.0331 in.)

Fig. 64: Measuring Groove Of High And Low Clutch SleeveCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift forkNo. 2

INSPECT FRONT DRIVE CLUTCH SLEEVE AND GEAR SHIFT FORK NO. 196.

Using vernier calipers, measure the thickness of the gear shift fork No. 1 claw.a.

Thickness: 10 mm (0.3937 in.)

Using vernier calipers, measure the groove of the front drive clutch sleeve.b.



Distance: 10.5 mm (0.4134 in.)

Calculate a clearance between the front drive clutch sleeve and gear shift fork No. 1c.

Standard clearance:

0.26 - 0.84 mm (0.0102 - 0.0331 in.)

Maximum clearance:

0.84 mm (0.0331 in.)

Fig. 65: Measuring Groove Of Front Drive Clutch SleeveCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

If the clearance exceeds the maximum, replace the front drive clutch sleeve or gear shift forkNo. 1.

INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCHSLEEVE

97.

Check that the tip of the spline gear of the front drive clutch sleeve is not worn.a.

Install the front drive clutch sleeve to the center differential case and check that the frontdrive clutch sleeve moves smoothly.

b.



Fig. 66: Inspecting Center Differential Case And High And Low Clutch SleeveCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE98.

Check that the tip of the spline gear of the front drive clutch sleeve is not worn.a.

Install the front drive clutch sleeve to the center differential case and check that the frontdrive clutch sleeve moves smoothly.

b.



Fig. 67: Inspecting Center Differential Case And Front Drive Clutch SleeveCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER CASE PLUG99.

REMOVE SPRING, COMPRESSION100.

REMOVE PIN, W/HEAD101.



Fig. 68: Removing Pin, W/HeadCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVE TRANSFER LOW PLANETARY RING GEAR102.

Using a screwdriver, remove the snap ring.a.



Fig. 69: Removing Snap Ring, Using ScrewdriverCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the low planetary ring gear from the front case.b.

INSTALL TRANSFER LOW PLANETARY RING GEAR103.

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



Fig. 70: Installing Transfer Low Planetary Ring GearCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Using a screwdriver, install the snap ring.b.



Fig. 71: Installing Snap Ring, Using ScrewdriverCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL PIN, W/HEAD104.

INSTALL SPRING, COMPRESSION105.

INSTALL TRANSFER CASE PLUG106.

Torque: 18.6 N.m (190 kgf.cm, 14 ft.lbf)



Fig. 72: Installing Transfer Case PlugCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER107.

INSTALL TRANSFER DRIVE SPROCKET BEARING108.

INSTALL TRANSFER DRIVE SPROCKET SUB-ASSY109.

INSTALL TRANSFER OUTPUT SHAFT SPACER NO. 1110.



Fig. 73: Installing Transfer Output Shaft Spacer No. 1Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING111.

Using SST and a press, install a new output shaft rear radial ball bearing.a.

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

NOTE: Install the output shaft rear radial ball bearing so that the bearingsnap ring groove faces to the rear.



Fig. 74: Installing Output Shaft Rear Radial Ball Bearing, Using SST And PressCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER SYNCHRONIZER RING SET112.



Fig. 75: Installing Transfer Synchronizer Ring SetCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL FRONT DRIVE CLUTCH SLEEVE113.



Fig. 76: Installing Front Drive Clutch SleeveCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL SYNCHROMESH SHIFTING KEY TRANSFER DRIVE114.

Install the 3 shifting keys to the clutch hub.a.

INSTALL TRANSFER SYNCHROMESH SHIFTING KEY SPRING115.

Install the 2 shifting key springs to the clutch hub.a.

NOTE: Position the shifting key springs so that their end gaps are notaligned.







Fig. 77: Installing Shifting Key Springs To Clutch HubCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER116.

INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING117.

INSTALL TRANSFER CLUTCH HUB118.



Fig. 78: Installing Transfer Clutch HubCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL CENTER DIFFERENTIAL CASE119.

INSTALL TRANSFER OUTPUT SHAFT SPACER BALL120.

INSTALL TRANSFER OUTPUT SHAFT SPACER NO. 2121.

INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING122.

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



Fig. 79: Installing Transfer Low Planetary Ring Gear Hole Snap RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECT DRIVE SPROCKET RADIAL CLEARANCE (See step 77)123.



Fig. 80: Inspecting Drive Sprocket Radial ClearanceCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECT DRIVE SPROCKET THRUST CLEARANCE (See step 76)124.



Fig. 81: Inspecting Drive Sprocket Thrust ClearanceCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER INPUT SHAFT BEARING125.

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

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



Fig. 82: Installing Bearing With Groove Facing Forward, Using SST And PressCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE126.

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



Fig. 83: Installing Spline Piece And Low Planetary Gear With Snap Ring, UsingScrewdriverCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER LOW PLANETARY GEAR BEARING127.

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

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

Bearing press in depth: 7.7 - 8.3 mm (0.303 - 0.327 in.)



Fig. 84: Using SST And Press, Drive In New BearingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING128.

Select a snap ring that allows the minimum axial play.a.

MARK AND THICKNESS SPECIFICATION

Mark Thickness mm (in.)

1 1.45 - 1.50 (0.0571 - 0.0591)

2 1.50 - 1.55 (0.0591 - 0.0610)

3 1.55 - 1.60 (0.0610 - 0.0630)

4 1.60 - 1.65 (0.0630 - 0.0650)

5 1.65 - 1.70 (0.0650 - 0.0669)

Using a snap ring expander, install a new snap ring.b.



Fig. 85: Installing Transfer Input Bearing Shaft Snap RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER INPUT SHAFT SEAL RING NO. 1129.

HINT:

Apply gear oil to the oil seal ring.•

Engage securely to eliminate clearance as shown in the illustration.•



Fig. 86: Installing Transfer Input Shaft Seal Ring No. 1Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER LOW PLANETARY GEAR BEARING130.

INSTALL TRANSFER THRUST BEARING RACE NO. 1131.

INSTALL SHAFT, TRANSFER INPUT132.



Fig. 87: Installing Shaft, Transfer InputCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL MANUAL TRANSFER PLANETARY CARR WASHER133.

INSTALL TRANSFER INPUT GEAR STOPPER BALL134.

INSTALL TRANSFER INPUT GEAR STOPPER135.



Fig. 88: Installing Transfer Input Gear StopperCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING136.

Select a input gear stopper snap ring that allows 0.05 -0.15 mm (0.0020 - 0.0059 in.)axial play.

a.



Fig. 89: Installing Transfer Input Gear Stopper Shaft Snap RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

THICKNESS SPECIFICATION


A 2.10 - 2.15 (0.0827 - 0.0846)

B 2.15 - 2.20 (0.0846 - 0.0866)

C 2.20 - 2.25 (0.0866 - 0.0886)

D 2.25 - 2.30 (0.0886 - 0.0906)

E 2.30 - 2.35 (0.0906 - 0.0925)

F 2.35 - 2.40 (0.0925 - 0.0945)

G 2.40 - 2.45 (0.0945 - 0.0965)

H 2.45 - 2.50 (0.0965 - 0.0984)

J 2.50 - 2.55 (0.0984 - 0.1004)

K 2.55 - 2.60 (0.1004 - 0.1024)

L 2.60 - 2.65 (0.1024 - 0.1043)

M 2.65 - 2.70 (0.1043 - 0.1063)




N 2.70 - 2.75 (0.1063 - 0.1083)

P 2.75 - 2.80 (0.1083 - 0.1102)

Q 2.80 - 2.85 (0.1102 - 0.1122)

R 2.85 - 2.90 (0.1122 - 0.1142)

S 2.90 - 2.95 (0.1142 - 0.1161)

T 2.95 - 3.00 (0.1161 - 0.1181)

U 3.00 - 3.05 (0.1181 - 0.1201)

Using a snap ring expander, install a new input gear stopper snap ring.b.

INSTALL TRANSFER CASE OIL SEAL137.

Using SST and a hammer, drive in a new oil seal until its surface is flush with the caseupper surface.

a.

SST 09316-60011 (09316-00011)

Coat the lip of the oil seal with MP grease.b.



Fig. 90: Installing Transfer Case Oil SealCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL LOW PLANETARY GEAR ASSY W/INPUT SHAFT SUB-ASSY138.

Install the low planetary gear assy and input shaft sub-assy.a.

Fig. 91: Installing Low Planetary Gear Assy W/Input Shaft Sub-AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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



Fig. 92: Installing Snap RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER OIL PUMP GEAR139.



Fig. 93: Installing Transfer Oil Pump GearCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER OIL PUMP BODY O-RING140.

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



Fig. 94: Installing Transfer Oil Pump Body O-RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER OIL PUMP BODY SUB-ASSY141.

Install the oil pump body sub-assy with the 3 bolts.a.

Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)



Fig. 95: Installing Oil Pump Body Sub-Assy With BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER CASE MAGNET142.

INSTALL TRANSFER OIL SEPARATOR SUB-ASSY143.

Install the oil separator sub-assy with the 3 bolts.a.

Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)



Fig. 96: Installing Oil Separator Sub-Assy With BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER CASE NO. 1 PLUG144.

Install the case No. 1 plug (filler plug) and a new gasket.a.

Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)

INSTALL TRANSFER CASE NO. 1 PLUG145.

Install the case No. 1 plug (drain plug) and a new gasket.a.


INSTALL TRANSFER SHIFT ACTUATOR ASSY146.

Install the actuator assy with the 3 bolts.a.


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



Fig. 97: Installing Actuator Assy With BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING147.

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

SST 09316-60011 (09316-00031)



Fig. 98: Installing Input Gear Radial Ball Bearing, Using SST And PressCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER DRIVEN SPROCKET BEARING148.

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



Fig. 99: Installing Transfer Driven Sprocket BearingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.



INSTALL NO. 2 STOPPER TRANSFER SHIFT SHAFT149.

Fig. 100: Installing No. 2 Stopper Transfer Shift ShaftCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL REAR OUTPUT SHAFT SUB-ASSY, GEAR SHIFT FORK NO. 1, FRONTDRIVE CLUTCH SLEEVE, FRONT DRIVE CHAIN AND DRIVEN SPROCKET

150.

Install the rear output shaft sub-assy, gear shift fork No. 1 and drive sprocket to the frontdrive chain.

a.



Fig. 101: Installing Rear Output Shaft Sub-Assy, And Drive Sprocket To FrontDrive ChainCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install the rear output shaft sub-assy, gear shift fork No. 1, front drive clutch sleeve, frontdrive chain and driven sprocket sub-assy to the case rear.

b.

HINT:

Check that the rear output shaft sub-assy and driven sprocket sub-assy turn lightly.



Fig. 102: Checking Rear Output Shaft Sub-Assy And Driven Sprocket Sub-AssyTurn LightlyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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



Fig. 103: Installing Snap RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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



Fig. 104: Using Screwdriver And Hammer, Drive In Snap RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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



Fig. 105: Using Screwdriver And Hammer, Drive In Snap RingCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL NO. 2 STOPPER TRANSFER SHIFT SHAFT151.

INSTALL OR ROLLER SHIFT INTER-LOCK PIN152.



Fig. 106: Installing No. 2 Stopper Transfer Shift ShaftCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER FRONT DRIVE SHIFT WORK SHAFT153.

Turn the front drive shift fork shaft, and install it on the rear case aligning the cut outposition and the inter-lock pin position.

a.

INSTALL TRANSFER SHIFT SHAFT STOPPER154.

Install the shift shaft stopper with the bolt.a.




Fig. 107: Installing Shift Shaft Stopper With BoltCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER GEAR SHIFT FORK NO. 2 W/TRANSFER HIGH AND LOWCLUTCH SLEEVE

155.

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

Install the bolt.b.


INSTALL TRANSFER OUTPUT SHAFT SPACER156.

INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING157.



Fig. 108: Installing Gear Shift Fork No. 2 And High And Low Clutch SleeveCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER CASE REAR158.

Apply FIPG to the case rear, as shown.a.

FIPG:

Part No. 08826-00090, THREE BOND 1281 or equivalent



Fig. 109: Applying FIPG To Case RearCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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




Fig. 110: Installing Clamp And Case Rear With BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL COLLAR159.

INSTALL TRANSFER OUTPUT WASHER160.



Fig. 111: Installing Transfer Output WasherCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL OIL (TRANSFER EXTENSION FRONT HOUSING SUB-ASSY) SEAL161.

Using SST and a hammer, drive in a new oil seal until its surface is flush with thehousing upper surface.

a.

SST 09223-46011, 09631-32020




Fig. 112: Using SST And Hammer, Drive In New Oil SealCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER EXTENSION HOUSING SUB-ASSY FRONT162.

Apply FIPG to the extension housing sub-assy rear, as shown.a.

FIPG:


Apply sealant to the bolt threads.b.

Sealant:

Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent



Fig. 113: Applying FIPG To Extension Housing Sub-Assy RearCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install the extension housing sub-assy rear with the 5 bolts.c.




Fig. 114: Installing Extension Housing Sub-Assy Rear With BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL163.

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

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


INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL164.

Drive in a new oil seal (rear) in the same way as the oil seal (front).a.

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



Fig. 115: Using SST And Hammer, Drive In Oil Seal (Front)Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSY165.

Install the companion flange sub-assy (front) to the drive sprocket sub-assy.a.

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

Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf)

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

SST 09330-00021

INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSY166.

Using SST, install the companion flange sub-assy (rear) in the same way as thecompanion flange sub-assy (front).

a.

Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf)

SST 09330-00021





Fig. 116: Installing Output Shaft Companion Flange Sub-AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL BREATHER OIL DEFLECTOR167.

INSTALL TRANSFER CASE COVER SUB-ASSY168.

Install the case cover sub-assy with the 4 bolts.a.


Fig. 117: Installing Case Cover Sub-Assy With BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER COVER TYPE T OIL SEAL169.

Using SST and a hammer, drive in a new oil seal until its surface is flush with the retainerupper surface.

a.




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

Fig. 118: Using SST And Hammer, Drive In Oil SealCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY170.

Apply FIPG to the front bearing retainer sub-assy, as shown.a.

FIPG:


Apply sealant to the bolt thread.b.

Sealant:

Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent



Fig. 119: Applying FIPG To Front Bearing Retainer Sub-AssyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install the front bearing retainer sub-assy with the 5 bolts.c.

Torque: 11.5 N.m (117 kgf.cm, 8 ft.lbf)



Fig. 120: Installing Front Bearing Retainer Sub-Assy With BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL HOSE171.

INSTALL TRANSFER ASSY172.

Install the transfer to the automatic transmission.a.

Install the 2 clamps and 8 bolts.b.




Fig. 121: Installing Clamps And BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (See REPLACEMENT )173.

CONNECT FRONT DIFFERENTIAL ASSY174.

INSTALL MANIFOLD STAY NO. 2 (See REPLACEMENT )175.

INSTALL MANIFOLD STAY (See REPLACEMENT )176.

INSTALL STARTER ASSY (See REPLACEMENT )177.

CONNECT WIRE HARNESS (See REPLACEMENT )178.

CONNECT CONNECTOR (See REPLACEMENT )179.

INSTALL FRAME CROSSMEMBER SUB-ASSY NO. 3 (See REPLACEMENT )180.

INSTALL TRANSFER CASE LOWER PROTECTOR)181.

Install the transfer case lower protector with the 4 bolts.a.




Fig. 122: Installing Transfer Case Lower Protector With BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALL TRANSMISSION CONTROL CABLE BRACKET NO. 1 (SeeREPLACEMENT )

182.

CONNECT TRANSMISSION CONTROL CABLE ASSY (See REPLACEMENT )183.

INSTALL OIL COOLER INLET TUBE NO. 1 (See REPLACEMENT )184.

SST 09023-12701

CONNECT OIL COOLER OUTLET TUBE NO. 1 (See REPLACEMENT )185.

SST 09023-12701

INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY (See REPLACEMENT )186.

INSTALL FRONT SUSPENSION MEMBER BRACKET LH (See REPLACEMENT )187.

INSTALL FRONT SUSPENSION MEMBER BRACKET (See REPLACEMENT )188.

ADD TRANSFER OIL189.

ADD AUTOMATIC TRANSMISSION FLUID (See REPLACEMENT )190.



INSPECT AUTOMATIC TRANSMISSION FLUID (See REPLACEMENT )191.

INSTALL PROPELLER SHAFT ASSY (See OVERHAUL )192.

INSTALL PROPELLER SHAFT ASSY FRONT (See OVERHAUL )193.

INSTALL EXHAUST PIPE ASSY (1GR-FE)194.

CONNECT OXYGEN SENSOR (See EXHAUST PIPE ASSY (1GR-FE) )195.

INSTALL ENGINE UNDER COVER ASSY REAR (See REPLACEMENT )196.

INSTALL ENGINE UNDER COVER SUB-ASSY NO. 1 (See REPLACEMENT )197.

INSPECT AUTOMATIC TRANSMISSION FLUID (See REPLACEMENT )198.

INSPECT SHIFT LEVER POSITION (See REPLACEMENT )199.

CHECK FOR EXHAUST GAS LEAKS200.

WARM UP201.

DRIVING TEST202.

© 2008 Mitchell Repair Information Co., LLC.



Documents

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