Transfer Assembly: Reassembly

INSPECT SHIFT FORK NO. 2 AND CLUTCH SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the shift fork No. 2 and clutch sleeve.
1. Standard clearance: 0.10 - 0.40 mm (0.0039 - 0,0157 In.)
2. Maximum clearance: 0.40 mm (0.0157 in.)
Fig 1: Measuring Clearance Between Shift Fork & Clutch Sleeve Using Feeler Gauge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL THE BEARING RACE (FOR THE OUTPUT SHAFT)
Using SST and a press, install the bearing race.
1. SST 09316-60011 (09316-00011, 09316-00031), 09950-60020 (09951-00890)
Fig 2: Installing Bearing Race For Output Shaft Using SST & Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL THE BEARING RACE (FOR THE IDLER GEAR)
Using SST and a press, install the bearing race.
1. SST 09316-60011 (09316-00011, 09316-00031), 09950-60020 (09951-00790)
INSTALL OIL RECEIVER TO FRONT CASE
Install the oil receiver and bolt.
1. Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)
Fig 4: Installing Oil Receiver & Bolt To Front Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT OUTER LEVER AND INNER LEVER
1. Install the shift inner lever, washer and outer lever to the front case.
2. Using a pin punch, hammer and socket wrench, tap in the lever lock pin.
3. Install the washer and nut to the shift outer lever.
  1. Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)
  Fig 5: Installing Lever Lock Pin Using Pin Punch, Hammer & Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ASSEMBLE SHIFT FORK NO. 1 AND SHIFT FORK NO. 1 SHAFT
1. Assemble the shift fork No. 1 and shift fork No. 1 shaft.
2. Using a pin punch and hammer, drive in the slotted spring pin.
  
  Fig 6: Driving Slotted Spring Pin Using Pin Punch & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND SHIFT FORK NO. 1 SHAFT TO FRONT CASE
NOTE: Set the shift inner lever into the fork head part of the shift fork No. 1 securely.

Fig 7: Installing Idler Gear Assembly With Center Differential Assembly

INSTALL INPUT SHAFT ASSEMBLY
INSTALL 2 BEARING RACES TO REAR CASE
ASSEMBLY FRONT CASE AND REAR CASE
1. Apply FIPG to the front case.
  1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
2. Assemble the front case and rear case.
3. Apply liquid sealer to the "A"bolt threads.
  1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
4. Install the 8 bolts.
  1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
  Fig 9: Installing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ASSEMBLE FRONT CASE AND REAR CASE
Using a snap ring expander, install the snap ring to the rear case.

Fig 10: Installing Snap Ring To Rear Case Using Snap Ring Expander
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CASE COVER
1. Apply FIPG to the rear case.
  1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
2. Install the case cover.
  
  Fig 11: Installing Rear Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply liquid sealer to the bolt threads.
  1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
4. Install the 5 bolts.
  1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
  Fig 12: Installing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL STRAINER TO REAR CASE
Install the oil strainer and 2 bolts.
1. Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf)
Fig 13: Installing Oil Strainer & Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SELECT ADJUSTING SHIM FOR IDLER GEAR REAR TAPER ROLLER BEARING
1. Using vernier calipers, measure dimension "A".
2. Lightly hole down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
  
  Fig 14: Measuring Dimension "A"
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a steel straight edge and feeler gauge, measure the clearance of dimension "B".
4. Calculate the required thickness of the adjusting shim.
  1. Thickness: Dimension "A"+ Dimension "B"+ [0.022 - 0.049 mm, (0.0009 - 0.0019 in.)]
  Fig 15: Measuring Clearance Of Dimension "B"
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. From Fig 16, select a shim so that its thickness is within the range of the calculation.
  
  Fig 16: Shim Thickness Specification Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SELECT ADJUSTING SHIM FOR OUTPUT SHAFT TAPER ROLLER BEARING
1. Using a steel straight edge and feeler gauge, measure the clearance of dimension "C".
2. Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
  
  Fig 17: Measuring Clearance Of Dimension "C"
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a steel straight edge and vernier calipers with depth gauge, measure dimension "D".
4. Dimension "D" is the straight edge thickness (Dimension "F") subtracted from dimension "E" in Fig 18 .
  1. Dimension "D": Dimension "E"- Dimension "F"
  Fig 18: Measuring Dimension "D", "E" & "F"
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a steel straight edge and vernier calipers with depth gauge, measure dimension "G".
6. Dimension "G"is the straight edge thickness (Dimension "F") subtracted from Dimension "H".
  1. Dimension "G": Dimension "H"- Dimension "F"
  Fig 19: Measuring Dimension "G", "H" & "F"
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Calculate the required thickness of the adjusting shim.
  1. Thickness: Dimension "G"- (Dimension "D"- Dimension "C") + [0.014 ~ 0.039 mm, (0.0006 ~ 0.0015 in.)]
8. From Fig 20, select a shim so that its thickness is within the range of the calculation.
  
  Fig 20: Shim Thickness Specification Table
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR EXTENSION HOUSING
1. Apply FIPG to the rear extension housing.
  1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
  Fig 21: Applying FIPG To Rear Extension Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rear extension housing and 9 bolts.
  1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
  Fig 22: Installing Rear Extension Housing & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ASSEMBLE SHIFT FORK NO. 2 SHAFT AND SHIFT FORK NO. 2
1. Install the shift fork No. 2 to the shift fork No. 2 shaft.
2. Install the 3 snap rings to the shift fork No. 2 shaft.
INSTALL CLUTCH SLEEVE WITH SHIFT FORK NO. 2 SHAFT AND SHIFT FORK NO. 2
HINT:

Make sure to install the clutch sleeve in the correct direction.

Fig 23: Installing Clutch Sleeve With Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT EXTENSION HOUSING
1. Apply FIPG to the front extension housing.
  1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
2. Install the front extension housing and 6 bolts.
  1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
  HINT:
  
  Set the clutch sleeve in differential lock condition.
INSTALL TRANSFER INDICATOR SWITCH
Install the 3 transfer indicator switches with 3 new gaskets.
1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
INSTALL BALL, SPRING AND SCREW
1. Install the ball and spring.
2. Apply liquid sealer to the screw plug threads.
  1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
3. Using a torx socket wrench (T40), install the screw plug.
  1. Torque: 19 N.m (190 kgf.cm, 14 ft.lbf)
  Fig 26: Installing Ball, Spring & Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT GEAR TO FRONT CASE
HINT:

Apply gear oil to the output gear.

NOTE: Do not turn the output gear.

Fig 27: Installing Output Gear To Front Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MOTOR ACTUATOR
1. Apply FIPG to the motor actuator.
  1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
  Fig 28: Applying FIPG To Motor Actuator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Set the motor actuator in differential lock condition.
  
  Fig 29: Setting Motor Actuator In Differential Lock Condition
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the motor actuator and 4 bolts.
  1. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
INSTALL SPEED SENSOR DRIVE GEAR
Install the driven gear and bolt.
1. Torque: 11 N.m (115 kgf.cm, 8 ft.lbf)
INSTALL BREATHER HOSE