Transfer Assembly: Disassembly

WARNING: This page is about a different car, the 2005 Lexus LX 470. However, it is still accessible from the selected car via links, so may be relevant.

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: Locating Bolts Motor Actuator
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REMOVE OUTPUT GEAR FROM FRONT CASE

Fig 2: Removing Output Gear From Front
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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
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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: Identifying Front Extension Housing
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REMOVE CLUTCH SLEEVE WITH SHIFT FORK NO. 2 SHAFT AND SHIFT FORK NO. 2

Fig 5: Removing Clutch Sleeve With Shift Fork
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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
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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.

Fig 7: Locating Rear Extension Housing
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REMOVE ADJUSTING SHIMS
REMOVE OIL STRAINER FROM REAR CASE
Remove the 2 bolts and oil strainer.

Fig 8: Locating Oil Strainer Bolts
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REMOVE CASE COVER
1. Remove the 5 bolts.
  
  Fig 9: Identifying Case Cover
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2. Using a brass bar and hammer, tap the case cover and remove it.
Fig 10: Taping Case Cover
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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 From Rear Case
  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: Locating Rear Case
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REMOVE 2 BEARING RACES FROM REAR CASE

Fig 13: Removing Bearing Races From Rear Case
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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
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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
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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
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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: Taping Out Lever Lock Pin
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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
  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: Driving In New Oil Seal
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IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL
1. Using SST and a hammer, drive out the oil seal.
  SST 09316-6001 1 (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 09316-6001 1 (09316-00011, 09316-00031)
Fig 20: Driving Out Oil Seal
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REMOVE OIL RECEIVER FROM FRONT CASE
Remove the bolt and oil receiver.

Fig 21: Removing Oil Receiver From Front Case
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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 Bearing Race (For Idler Gear)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, remove the bearing race (for the output shaft).
Fig 23: Removing Bearing Race (For Output Shaft)
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