Transfer Assembly: Reassembly

INSTALL CENTER DIFFERENTIAL CLUTCH CONTROL VALVE
1. Install the center differential clutch control valve sleeve, transfer direct clutch modulator valve spring, center differential clutch control valve and center differential clutch control valve plug to the transfer upper valve body.
  
  Fig 1: Identifying Center Differential Clutch Control Valve Plug, Valve, Transfer Direct Clutch Modulator Valve Spring And Center Differential Clutch Control Valve Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. While pushing on the center differential control valve plug, install the center differential clutch control valve seat on the transfer upper valve body.
  
  Fig 2: Identifying Center Differential Clutch Control Valve Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER SOLENOID MODULATOR VALVE
1. Install the low-high shift valve compression spring, transfer solenoid modulator valve and transfer solenoid modulator valve plug to the transfer upper valve body.
  
  Fig 3: Identifying Low-High Shift Valve Compression Spring, Transfer Solenoid Modulator Valve And Valve Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. While pushing on the transfer solenoid modulator valve plug, install the transfer solenoid modulator valve plug seat on the transfer upper valve body.
  
  Fig 4: Identifying Transfer Solenoid Modulator Valve Plug Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER VALVE BODY COVER
1. Install the solenoid oil strainer to the transfer valve body cover.
2. Install the transfer valve body cover and transfer valve body plate upper to the transfer upper valve body.
  
  Fig 5: Identifying Transfer Valve Body Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 6 bolts.
  Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
  
  HINT:
  
  Bolt length:
  
  Fig 6: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Bolt A: 35 mm (1.38 in.)
  - Bolt B: 20 mm (0.79 in.)
INSTALL TRANSFER CONTROL SOLENOID
1. Install the transfer control solenoid and solenoid lock plate to the transfer upper valve body with the bolt.
  Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf)
  
  Fig 7: Identifying Transfer Control Solenoid Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Install the solenoid lock plate into the cutout on the transfer control solenoid.
INSTALL TRANSFER DRIVE SPROCKET BEARING
1. Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket.
  SST 09950-70010 (09951-07100), 09950-60010 (09951-00640), 09316-20011
  
  Fig 8: Identifying Transfer Drive Sprocket Bearing To Transfer Drive Sprocket Using SST (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket.
  SST 09316-60011 (09316-00011)
  
  NOTE:
  Install the transfer drive sprocket bearing with the shield facing upward.
  
  Fig 9: Identifying Transfer Drive Sprocket Bearing To Transfer Drive Sprocket Using SST (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER DRIVEN SPROCKET BEARING
1. Using SST and a press, install a new transfer driven sprocket bearing to the transfer front driven clutch sleeve.
  
  Fig 10: Identifying Transfer Driven Sprocket Bearing To Transfer Front Driven Clutch Sleeve (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-70010 (09951-07100), 09950-60010 (09951-00640), 09316-20011
2. Using SST and a press, install a new transfer driven sprocket bearing to the transfer front driven clutch sleeve.
  
  Fig 11: Identifying Transfer Driven Sprocket Bearing To Transfer Front Driven Clutch Sleeve (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09316-60011 (09316-00011, 09316-00041)
INSTALL TRANSFER CENTER SUPPORT SEAL RING
1. Coat the 2 seal rings with ATF.
2. Compress the 2 transfer center support seal rings as shown in the illustration and install them into the grooves on the transfer center support.
  
  Fig 12: Identifying Transfer Center Support Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not expand the ring ends excessively.
  - If any ring is damaged or deformed, replace it with a new one.
INSTALL TRANSFER CENTER SUPPORT
1. Install the transfer center support to the transfer chain case rear with the 5 bolts.
  Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
2. Coat 2 new O-rings with ATF.
3. Install the 2 O-rings to the screws.
4. Install the 2 gaskets and 2 screws to the transfer chain case rear.
  
  Fig 13: Identifying Transfer Center Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)

INSTALL TRANSFER DIRECT CLUTCH PISTON O-RING

Coat 2 new O-rings with ATF.

Install the 2 O-rings to the transfer direct clutch piston.

Fig 14: Identifying Transfer Direct Clutch Piston O-Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

O-ring size:

O-RING SPECIFICATIONS

Installation position	Inner diameter mm (in.)	Thickness mm (in.)
Inner	56.45 to 57.45 (2.222 to 2.262)	2.54 to 2.70 (0.100 to 0.106)
Outer	116.20 to 117.80 (4.575 to 4.638)	3.0 to 3.2 (0.118 to 0.126)

INSTALL CENTER DIFFERENTIAL CLUTCH PISTON
1. Install the center differential clutch piston to the transfer direct clutch drum.
  
  Fig 15: Identifying Center Differential Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not damage the O-rings.
INSTALL TRANSFER DIRECT CLUTCH RETURN SPRING
1. Install the transfer direct clutch return spring to the transfer direct clutch drum.
  
  Fig 16: Identifying Transfer Direct Clutch Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER
1. Coat the rubber on the center differential clutch pressure balancer with ATF.
2. Install the center differential clutch pressure balancer to the transfer direct clutch drum.
  
  Fig 17: Locating Rubber On Center Differential Clutch Pressure Balancer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place SST on the center differential clutch pressure balancer, and compress the return spring with a press.
  SST 09350-30020 (09350-07040)
4. Using SST, install the snap ring.
  SST 09350-30020 (09350-07040, 09350-07070)
  
  Fig 18: Identifying Snap Ring Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CENTER DIFFERENTIAL CLUTCH DISC SET

Install the 2 center differential clutch disc flanges and center differential clutch disc set to the transfer direct clutch drum.
HINT:
- A: Center differential clutch disc flange (No.1)
- B: Center differential clutch disc set (Discs)
- C: Center differential clutch disc set (Plates)
- D: Center differential clutch disc flange (No.2)
  Install in the following order: A - B - C - B - C - B - C - B -C - B - D
  
  Fig 19: Identifying Center Differential Clutch Disc Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
- A: thickness 2.95 to 3.45 mm (0.116 to 0.136 in.)
- B: thickness 1.99 to 2.09 mm (0.078 to 0.082 in.)
- C: thickness 1.95 to 2.05 mm (0.077 to 0.081 in.)
- D: thickness 2.95 to 3.05 mm (0.116 to 0.120 in.)
NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
Using a screwdriver with its tip taped, install the snap ring to the transfer direct clutch drum.

Fig 20: Identifying Snap Ring To Transfer Direct Clutch Drum Using Screwdriver
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the transfer direct clutch drum to the transfer center support.

Fig 21: Identifying Transfer Direct Clutch Drum To Transfer Center Support
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Set the dial indicator perpendicular to the flange.
Apply air (200 kpa, 2.0 kgf*cm² , 19 psi) at the oil hole as shown in the illustration. Measure the pack clearance.

Fig 22: Measuring Pack Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard:

0.40 to 0.80 mm ( 0.016 to 0.031 in.)

HINT:
- Check that the piston moves smoothly.
- Perform the measurement at 2 or 3 points and take the average.

If the clearance is not within the specified range, select another center differential clutch disc flange (No.1).

Fig 23: Identifying Clutch Flange Thickness

Flange thickness:

FLANGE THICKNESS SPECIFICATIONS

Thickness mm (in.)	Mark
2.95 to 3.05 (0.116 to 0.120)	90
3.15 to 3.25 (0.124 to 0.128)	91
3.35 to 3.45 (0.132 to 0.136)	92

Remove the transfer direct clutch drum from the transfer center support.

Fig 24: Identifying Transfer Direct Clutch Drum From Transfer Center Support
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSFER REAR OUTPUT SHAFT BEARING
1. Install the transfer rear output shaft bearing to the transfer direct clutch drum.
  
  Fig 25: Identifying Transfer Rear Output Shaft Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER REAR OUTPUT SHAFT AND CENTER DIFFERENTIAL CARRIER
1. Install the transfer rear output shaft and center differential carrier to the transfer direct clutch drum.
  
  Fig 26: Identifying Transfer Rear Output Shaft And Center Differential Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE FRONT OIL SEAL
1. Using SST and a hammer, install a new oil seal.
  SST 09316-60011 (09316-00011, 09316-00071)
  
  Oil seal drive in depth:
  
  5.6 to 6.2 mm (0.220 to 0.244 in.)
2. Apply MP grease to the oil seal lip.
  
  Fig 27: Identifying Transfer Case Front Oil Seal Using SST And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CHAIN CASE GOVERNOR APPLY GASKET
1. Coat 2 new gaskets with ATF.
2. Install the 2 gaskets to the transfer chain case rear.
  
  Fig 28: Identifying Transfer Chain Case Governor Apply Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat a new O-ring and 2 new gaskets with ATF.
4. Install the O-ring to the screw.
5. Install the 2 gaskets and screw to the transfer chain case front.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 29: Identifying Gaskets And Screw To Transfer Chain Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER BAFFLE VALVE SUBASSEMBLY
1. Install the transfer baffle valve to the transfer chain case rear with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
  
  Fig 30: Identifying Transfer Baffle Valve To Transfer Chain Case Rear With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE BEARING
1. Using SST and a press, install the transfer case bearing to the transfer case.
  SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
  
  Fig 31: Identifying Transfer Case Bearing Using SST And Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bearing drive in depth:
  
  94.6 to 94.9 mm (3.724 to 3.736 in.)
INSTALL TRANSFER CASE REAR OIL SEAL
1. Using SST and a hammer, install a new oil seal.
  SST 09325-40010
  
  Oil seal drive in depth: 2.3 to 2.7mm (0.091 to 0.106 in.)
  
  Fig 32: Identifying Transfer Case Rear Oil Seal Using SST And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply MP grease to the oil seal lip.
3. Install the clamp to the transfer case with the bolt.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 33: Identifying Clamp To Transfer Case With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR
1. Using SST and a press, install a new transfer extension housing dust deflector to the transfer case.
  SST 09950-70010 (09951-07150), 09950-60020 (09951-00910)
  
  Fig 34: Identifying Transfer Extension Housing Dust Deflector Using SST And Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CHAIN CASE FRONT
1. Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol.
2. Apply seal packing to the transfer chain case front as shown in the illustration.
  Seal packing:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
  
  Fig 35: Applying Seal Packing To Transfer Chain Case Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily tighten the 6 bolts in several steps, and then tighten to the specified torque.
  Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf)
  
  HINT:
  
  Bolt length:
  
  Fig 36: Identifying Tightening Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Bolt A: 57 mm (2.24 in.)
  - Bolt B: 74 mm (2.91 in.)
  - Other bolts: 45 mm (1.77 in.)
INSTALL TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVE SPROCKET ASSEMBLY AND TRANSFER FRONT DRIVEN CLUTCH SLEEVE ASSEMBLY

Fig 37: Identifying Transfer Front Drive Chain
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the transfer front drive chain to the transfer drive sprocket and transfer front driven clutch sleeve.
2. Install the transfer front drive chain, transfer drive sprocket and transfer front drive clutch sleeve.
INSTALL TRANSFER CHAIN CASE REAR
1. Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol.
2. Apply seal packing to the transfer chain case front as shown in the illustration.
  Seal packing:
  
  Fig 38: Applying Seal Packing To Transfer Chain Case Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
3. Temporarily tighten the 10 bolts in several steps, and then tighten to the specified torque.
  Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf)
  
  HINT:
  
  Fig 39: Identifying Tightening Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt length:
  - Bolt A: 60 mm (2.36 in.)
  - Bolt B: 50 mm (1.97 in.)
  - Bolt C: 109 mm (4.29 in.)
  - Other bolts: 40 mm (1.57 in.)
INSTALL FLANGE YOKE
1. Install the flange yoke.
2. Using SST, hold the yoke.
  SST 09213-54015, 09330-00021
3. Using a deep socket wrench (30 mm), torque the nut.
  Torque: 123 N*m (1,254 kgf*cm, 91 ft.*lbf)
4. Using a chisel and hammer, stake the nut.
  
  Fig 40: Identifying Flange Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER REAR OUTPUT SHAFT ASSEMBLY
1. Install the transfer rear output shaft.
  
  Fig 41: Identifying Transfer Rear Output Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER CASE
1. Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol.
2. Apply seal packing to the transfer chain case front as shown in the illustration.
  Seal packing:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
  
  Fig 42: Applying Seal Packing To Transfer Chain Case Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily tighten the 8 bolts and clamp in several steps, and then tighten to the specified torque.
  Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf)
  
  HINT:
  
  Bolt length:
  
  Fig 43: Identifying Tightening Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Bolt A: 88 mm (3.46 in.)
  - Bolt B: 40 mm (1.57 in.)
INSTALL TRANSFER VALVE BODY ASSEMBLY
1. Coat the transfer wire O-ring with ATF.
  
  Fig 44: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transfer wire with the bolt.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 45: Identifying Transfer Wire With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the transfer wire connector to the transfer control solenoid.
4. Install the transfer valve body assembly with the 4 bolts.
  
  Fig 46: Identifying Transfer Valve Body Assembly Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
INSTALL TRANSFER OIL PAN
1. Install the transfer oil cleaner magnet to the transfer oil pan.
  
  Fig 47: Locating Transfer Oil Cleaner Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol.
3. Apply seal packing to the transfer chain case front as shown in the illustration.
  
  Fig 48: Applying Seal Packing To Transfer Chain Case Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Seal packing:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
4. Temporarily tighten the 9 bolts in several steps, and then tighten to the specified torque.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 49: Identifying Tightening Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002