Transfer Assembly: Disassembly

REMOVE BREATHER HOSE
REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR
Remove the bolt and driven gear.
REMOVE MOTOR ACTUATOR
Remove the 4 bolts and motor actuator.

Fig 1: Removing Motor Actuator Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT GEAR FROM FRONT CASE

Fig 2: Removing Output Gear From Front Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SCREW PLUG, SPRING AND BALL
1. Using a torx socket wrench (T40), remove the screw plug.
  
  Fig 3: Removing Screw Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a magnetic finger, remove the spring and ball.
REMOVE TRANSFER INDICATOR SWITCH
Remove the 3 transfer indicator switches and 3 gaskets.
REMOVE FRONT EXTENSION HOUSING
Remove the 6 bolts and front extension housing.

NOTE: If necessary, tap the front extension housing lightly with a plastic hammer.

Fig 4: Removing Front Extension Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH SLEEVE WITH SHIFT FORK NO. 2 SHAFT AND SHIFT FORK NO. 2

Fig 5: Removing Clutch Sleeve With Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE SHIFT FORK NO. 2 SHAFT AND SHIFT FORK NO. 2
1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the shift fork No. 2 shaft.
2. Separate the shift fork No. 2 shaft and shift fork No. 2.
REMOVE REAR EXTENSION HOUSING
Remove the 9 bolts and rear extension housing.

NOTE: If necessary, tap the rear extension housing lightly with a plastic hammer.
REMOVE ADJUSTING SHIMS

Fig 7: Removing Rear Extension Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER FROM REAR CASE
Remove the 2 bolts and oil strainer.

Fig 8: Removing Oil Strainer Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CASE COVER
1. Remove the 5 bolts.
  
  Fig 9: Removing Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap the case cover and remove it.
  
  Fig 10: Removing Case Cover Using Brass Bar And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE FRONT CASE AND REAR CASE
1. Using a snap ring expander, remove the snap ring from the rear case.
2. Remove the 8 bolts.
3. Using a brass bar and hammer, tap the rear case and separate it.
REMOVE 2 BEARING RACES FROM REAR CASE

Fig 13: Removing Bearing Races
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT ASSEMBLY
Using a plastic hammer, remove the input shaft assembly from the front case.

Fig 14: Removing Input Shaft Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND SHIFT FORK NO. 1 SHAFT FROM FRONT CASE

Fig 15: Removing Idler Gear Assembly With Center Differential Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE SHIFT FORK NO. 1 AND SHIFT FORK NO. 1 SHAFT
1. Using a pin punch and hammer, drive out the slotted spring pin.
2. Separate the shift fork No. 1 and shift fork No. 1 shaft.
  
  Fig 16: Separating Shift Fork No 1 And Shift Fork No 1 Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT OUTER LEVER AND INNER LEVER
1. Remove the nut and washer from the shift outer lever.
2. Using a brass bar, hammer and socket wrench, tap out the lever lock pin.
3. Remove the shift outer lever, washer and inner lever from the front case.
IF NECESSARY, REPLACE INNER SHIFT LEVER OIL SEAL
1. Using a screwdriver, pry out the oil seal from the front case.
  
  Fig 18: Removing Inner Shift Lever Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply MP grease to the lip of a new oil seal.
  
  Fig 19: Installing New Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a hammer, drive in a new oil seal.
  SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)
IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL
1. Using SST and a hammer, drive out the oil seal.
  
  Fig 20: Removing Input Shaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09316-60011 (09316-00011)
2. Apply MP grease to the lip of a new oil seal.
3. Using SST and a hammer, drive in a new oil seal.
  SST 09316-60011 (09316-00011,09316-00031)
REMOVE OIL RECEIVER FROM FRONT CASE
Remove the bolt and oil receiver.

Fig 21: Removing Oil Receiver Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2 BEARING RACES FROM FRONT CASE
1. Using SST, remove the bearing race (for the idler gear).
  
  Fig 22: Removing Bearing Races From Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010), 09950-60010 (09951-00320)
2. Using a brass bar and hammer, remove the bearing race (for the output shaft).
  
  Fig 23: Removing Bearing Race For Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002