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 Bolts And Motor Actuator
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.
2. Using a magnetic finger, remove the spring and ball.
Fig 3: Removing Screw Plug, Spring And Ball
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

HINT:

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

Fig 4: Removing Bolts And 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 Shaft
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.
  
  Fig 6: Taping Out Snap Rings From Shift Fork Shaft Using Screwdrivers And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR EXTENSION HOUSING
Remove the 9 bolts and rear extension housing.

HINT:

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

Fig 7: Removing Bolts And 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 Bolts And Oil Strainer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CASE COVER
1. Remove the 5 bolts.
  
  Fig 9: Removing Case Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap the case cover and remove it.
  
  Fig 10: Taping And Removing Case Cover Using A 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.
  
  Fig 11: Removing Snap Ring Using Snap Ring Expander
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 8 bolts.
3. Using a brass bar and hammer, tap the rear case and separate it.
  
  Fig 12: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2 BEARING RACES FROM REAR CASE

Fig 13: Removing Bearing Races From Rear Case
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 From Front Case Using Plastic Hammer
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
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: Driving Out Slotted Spring Pin Using Pin Punch And Hammer
  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.
  
  Fig 17: Tap Out Lever Lock Pin Using Brass Bar, Hammer And Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
IF NECESSARY, REPLACE INNER SHIFT LEVER OIL SEAL
1. Using a screwdriver, pry out the oil seal from the front case.
  
  Fig 18: Prying Out Oil Seal From Front Case Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 09950-60010 (09951-00270), 09950-70010 (09951-07150)
  
  Fig 19: Installing Inner Shift Lever Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL
1. Using SST and a hammer, drive out the oil seal.
  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)
  
  Fig 20: Installing Input Shaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL RECEIVER FROM FRONT CASE
Remove the bolt and oil receiver.

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