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Disassembly [10/2022 - ]: Procedure

  1. REMOVE CLUTCH CONTROL SOLENOID WIRE 
    1. Disconnect the 3 clamps and 2 connectors.
      GTY1117964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts, 3 wiring harness clamp brackets and clutch control solenoid wire from the transfer assembly.
      GTY1110705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. Using 2 nuts, remove the 4 transfer and transaxle setting stud bolts from the transfer assembly.
      GTY1110700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. SECURE TRANSFER ASSEMBLY 
    1. Secure the transfer assembly to the overhaul attachment.
      GTY918001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 2 transfer case straight pins from the transfer assembly.
      GTY917978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 1 TRANSFER CASE PLUG 
    1. Remove the No. 1 transfer case plug and gasket from the transfer assembly.
      GTY1110701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE TRANSFER DRAIN PLUG 
    1. Using a 10 mm socket hexagon wrench, remove the transfer drain plug and gasket from the transfer assembly.
      GTY917977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE TRANSFER FILLER PLUG 
    1. Using a 10 mm socket hexagon wrench, remove the transfer filler plug and gasket from the transfer assembly.
      GTY917976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE NO. 1 4 WHEEL DRIVE POSITION SWITCH 
    1. Remove the No. 1 4 wheel drive position switch from the transfer assembly.
      GTY1110702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE TRANSFER CASE BREATHER PLUG 
    1. Remove the transfer case breather plug from the transfer assembly.
      GTY1110696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE TRANSFER CASE OIL SEAL 

    See step  4 [10/2022 - 11/2023], or see step  4 [11/2023 - ]

  11. REMOVE TRANSFER CASE OIL SEAL RH 
    1. Using SST, remove the transfer case oil seal RH from the transfer assembly.
      GTY1114117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transfer Case Oil Seal RH
      • SST: 09308-00010 
      NOTE:

      Do not scratch the press-fitting surface of the transfer case oil seal RH.

  12. INSPECT TOTAL PRELOAD 
    NOTE:
    • When replacing the transfer output shaft companion flange sub-assembly and transfer case oil seal, be sure to check the preload.
    • If the transfer output shaft companion flange sub-assembly and transfer case oil seal were replaced without checking the preload, replace the transfer assembly.
    1. Using a torque wrench, check the total preload (starting torque) with the teeth of the transfer driven pinion and transfer ring gear in contact.
      GTY848601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • The torque wrench should be installed as shown in the illustration.
      • Record the measured value as it is used during assembly.
  13. REMOVE OUTPUT SHAFT COMPANION FLANGE NUT 
    1. Place a matchmark on the transfer output shaft companion flange sub-assembly as shown in the illustration.
      GTY1111883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
      *b Transfer Driven Pinion

      HINT: 

      Place a matchmark aligned with the groove on the transfer driven pinion.

    2. Using a screwdriver and hammer, unstake the output shaft companion flange nut.
      GTY873553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Transfer Driven Pinion
      NOTE:
      • Completely unstake the output shaft companion flange nut.
      • Do not damage the threads of the transfer driven pinion.
    3. Remove the output shaft companion flange nut from the transfer assembly.
  14. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using SST, remove the transfer output shaft companion flange sub-assembly from the transfer assembly.
      GTY879104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09950-30012 
        1. 09951-03010
        2. 09953-03010
        3. 09954-03010
        4. 09955-03030
      • SST: 09956-03090 
  15. REMOVE TRANSFER CASE OIL SEAL 

    See step  7 [10/2022 - 11/2023], or see step  7 [11/2023 - ]

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