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Reassembly [10/2022 - ]: Procedure

  1. INSTALL TRANSFER CASE OIL SEAL 

    See step  8 [10/2022 - 11/2023], or see step  8 [11/2023 - ]

  2. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Align the matchmark on the transfer output shaft companion flange sub-assembly with the transfer driven pinion groove, and then temporarily install the transfer output shaft companion flange sub-assembly to the transfer assembly as shown in the illustration.
      GTY1109555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
      *b Transfer Driven Pinion
    2. Using SST, install the transfer output shaft companion flange sub-assembly.
      GTY891350Courtesy 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 
    3. Using SST, temporarily install a new output shaft companion flange nut to the transfer assembly.
      GTY886110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09330-00021 

      Torque: 140 N.m (1428 kgf/cm, 103 ft.lbf) 

      WARNING:

      The total preload may be within the standard even when the transfer output shaft companion flange sub-assembly is loose. If the transfer output shaft companion flange sub-assembly is installed in this state, the vehicle may be damaged or lead to a serious accident.

      NOTE:

      Tighten the output shaft companion flange nut until there is no more looseness in the transfer output shaft companion flange sub-assembly and it turns to the right and left with the same amount of force.

      HINT: 

      After temporarily installing the output shaft companion flange nut, be sure to adjust the preoload.

  3. INSPECT TOTAL PRELOAD 
    1. Using a torque wrench, measure 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.
      • For a more accurate measurement, rotate the bearing forward and backward several times before the measurement.
      • Use the preload value measured prior to disassembling the transfer assembly as the standard value.
      • Adjust within the standard value (Adjustable range within +/- 0.2 N.m of the measured preload value).
    2. If the preload is not as specified, perform the procedures below.
      1. If the measured preoload is higher than the standard value:

        Replace the rear drive pinion bearing and transfer pinion bearing spacer, and then adjust the preload again.

      2. If the measured preoload is lower than the standard value:

        Tighten the output shaft companion flange nut, and then adjust the preload again.

  4. INSTALL OUTPUT SHAFT COMPANION FLANGE NUT 
    1. Place a matchmark on SST as shown in the illustration.
      GTY860716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
      • SST: 09930-42010 
    2. Install SST aligned with the matchmark on the transfer output shaft companion flange sub-assembly as shown in the illustration.
      GTY1111428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
    3. Using SST and a hammer, stake the output shaft companion flange nut.
      GTY921264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Check that the matchmarks are properly aligned.

  5. INSTALL TRANSFER CASE OIL SEAL RH 
    1. Coat the lip of a new transfer case oil seal RH with MP grease.
    2. Using SST and a hammer, tap in the transfer case oil seal RH to the transfer assembly as shown in the illustration.
      GTY1117455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transfer Case Oil Seal RH
      *a Depth
      • SST: 09223-46011 
      • SST: 09631-32020 

      Standard Depth

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      NOTE:
      • Tap the transfer case oil seal RH uniformly so that the transfer case oil seal RH is straight.
      • Do not tap the transfer case oil seal RH in too far.
  6. INSTALL TRANSFER CASE OIL SEAL 

    See step  5 [10/2022 - 11/2023], or see step  5 [11/2023 - ]

  7. INSTALL TRANSFER CASE BREATHER PLUG 
    1. Install a new transfer case breather plug to the transfer assembly.
      GTY1110695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 11.3 N.m (115 kgf/cm, 8 ft.lbf) 

  8. INSTALL NO. 1 4 WHEEL DRIVE POSITION SWITCH 
    1. Using SST, install the No. 1 4 wheel drive position switch to the transfer assembly.
      GTY1117720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09816-30010 

      Torque: 40.2 N.m (410 kgf/cm, 30 ft.lbf) 

      NOTE:

      Make sure that the gasket does not come off.

  9. INSTALL TRANSFER FILLER PLUG 
    1. Using a 10 mm socket hexagon wrench, install the transfer filler plug and a new gasket to the transfer assembly.
      GTY917976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 39 N.m (398 kgf/cm, 29 ft.lbf) 

  10. INSTALL TRANSFER DRAIN PLUG 
    1. Using a 10 mm socket hexagon wrench, install the transfer drain plug and a new gasket to the transfer assembly.
      GTY917977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 39 N.m (398 kgf/cm, 29 ft.lbf) 

  11. INSTALL NO. 1 TRANSFER CASE PLUG 
    1. Install the No. 1 transfer case plug and a new gasket to the transfer assembly.
      GTY1117961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 39 N.m (398 kgf/cm, 29 ft.lbf) 

  12. INSTALL TRANSFER CASE STRAIGHT PIN 
    1. Using a plastic hammer, install the 2 transfer case straight pins to the transfer assembly at the positions shown in the illustration.
      GTY1116891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Protrusion Height

      10.8 to 11.8 mm (0.425 to 0.465 in.)

  13. REMOVE TRANSFER ASSEMBLY 
    1. Remove the transfer assembly from the overhaul attachment.
      GTY918001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. Clean the 4 bolt holes.
    2. Using 2 nuts, install 4 new transfer and transaxle setting stud bolts to the transfer assembly at the positions shown in the illustration.
      GTY1119250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Sealed Side

      Torque: 39.2 N.m (400 kgf/cm, 29 ft.lbf) 

      NOTE:

      Install the sealed side of the transfer and transaxle setting stud bolt to the transfer assembly.

  15. INSTALL CLUTCH CONTROL SOLENOID WIRE 
    1. Install the 3 wiring harness clamp brackets and clutch control solenoid wire to the transfer assembly with the 3 bolts.
      GTY1114491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Wiring Harness Clamp Bracket
      *2 Clutch Control Solenoid Wire

      Torque: 19.6 N.m (200 kgf/cm, 14 ft.lbf) 

      HINT: 

      Tighten the ground of the clutch control solenoid wire together with the bolt (A).

    2. Connect the 3 clamps and 2 connectors.
      GTY1117964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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