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Transfer Assembly: Disassembly

  1. REMOVE VEHICLE SPEED SENSOR 

    Torque: 11.5 N.m (115 kgf.cm, 8 ft.lbf) 

  2. w/ One Touch 2-4 selector system and A/T: 

    REMOVE L4 POSITION SWITCH 

    Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

  3. w/o One Touch 2-4 selector system: 

    REMOVE 4WD POSITION SWITCH 

    Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

  4. A/T: 

    REMOVE NEUTRAL POSITION SWITCH 

    Torque: 37 N.m (380 kg.fcm, 27 ft.lbf) 

  5. REMOVE PLUGS OF FRONT CASE 

    Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

    NOTE:

    At the time of installation, check the following items.

    • The input shaft and output shafts rotate smoothly.
    • Shifting can be made smoothly to all position.

  6. REMOVE PROTECTOR Remove the 4 bolts and protector. 

    Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

  7. 3RZ-FE A/T: 

    REMOVE SHIFT GEAR HEAD No. 1 AND No. 2 

    1. Using a pin punch and hammer, drive out the 2 slot spring pins.
      Fig 1: Removing Shift Gear Heads
      G02845588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 shift gear heads.

  8. REMOVE FRONT BEARING RETAINER 
    1. Remove the 5 bolts.
      Fig 2: Removing Front Bearing Retainer Bolts
      G02845589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 11.5 N.m (115 kgf.cm, 8 ft.lbf) 

      NOTE:

      At the time of installation, apply liquid sealer to the bolts.

      Sealant: 

      Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    2. Using a plastic hammer, tap the front bearing retainer and remove it.
      NOTE:

      At the time of installation, please refer to the following items.

      • Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the front bearing retainer.
      • Apply FIPG to the front bearing retainer, as shown in Fig 3.

    Fig 3: Applying FIPG To Front Bearing Retainer
    G02845590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 

  9. 3RZ-FE A/T: 

    REMOVE UPPER COVER, 2 GASKETS AND OIL DEFLECTOR 

    Remove the 4 bolts, upper cover, 2 gaskets and oil deflector.

    Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    NOTE:

    At the time of installation, install a new gasket.

  10. EXCEPT 3RZ-FE A/T: 

    REMOVE CONTROL RETAINER, GASKET AND OIL DEFLECTOR 

    NOTE:

    At the time of installation, install a new gasket.

    1. Remove the 4 bolts, control retainer, gasket and oil deflector.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    2. w/o One Touch 2-4 selector system:

      Remove the select return spring from the control retainer.

  11. REMOVE FRONT COMPANION FLANGE 
      NOTE:

      At the time of installation, stake a new lock nut.

    1. Using a chisel and hammer, loosen the staked part of the nut.
    2. Using SST to hold the flange, remove the companion flange lock nut.
      Fig 4: Removing Companion Flange Lock Nut
      G02845591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09330-00021

      Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf) 

    3. Using SST, remove the companion flange.

      SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)

  12. REMOVE REAR COMPANION FLANGE 

    Remove the rear companion flange in the same way as the front companion flange.

    Fig 5: Removing Companion Flange Using SST
    G02845592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    At the time of installation, please refer to the following items.

    • Front companion flange bolts are slim.
    • Rear companion flange bolts are thick.

  13. REMOVE EXTENSION HOUSING 
    1. Remove the 5 bolts.

      Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

      NOTE:

      At the time of installation, apply liquid sealer to the bolts.

      Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    2. Using a plastic hammer, tap the extension housing and remove it.
    NOTE:

    At the time of installation, please refer to the following items.

    • Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the extension housing.
    • Apply FIPG to the extension housing, as shown in Fig 6.

    Fig 6: Applying FIPG To Extension Housing
    G02845593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent 

  14. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR 
    1. Remove the vehicle speed sensor drive gear.
      NOTE:

      At the time of installation, please refer to the following item. Make sure to install the drive gear in the correct direction.

    2. Using a magnetic finger, remove the ball from the rear output shaft.
  15. SEPARATE FRONT CASE AND REAR CASE 
    1. Remove the 12 bolts.

      Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) 

    2. Using a screwdriver, separate the front case and rear case.
    NOTE:

    At the time of installation, please refer to the following items.

    • Shift the high and low sleeve to low side (rear side) and assemble the front case and rear case.
    • Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the rear case.
    • Apply FIPG to the rear case, as shown in Fig 7.

    Fig 7: Applying FIPG To Rear Case
    G02845594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent 

  16. REMOVE STRAIGHT SCREW PLUG, SPRING AND LOCKING BALL 
    1. Using a hexagon wrench, remove the 1 or 2 screws.
      Fig 8: Removing Screws Using Hexagon Wrench
      G02845595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 18.6 N.m (190 kgf.cm, 14 ft.lbf) 

      NOTE:

      At the time of installation, apply liquid sealer to the plugs.

      Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    2. Using a magnetic finger, remove the 1 or 2 springs and balls from the holes.
      Fig 9: Removing Springs And Balls From Both Holes Using A Magnetic Finger
      G02845596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. W/ ONE TOUCH 2-4 SELECTOR SYSTEM: 

    REMOVE HIGH AND LOW FORK SHAFT, SHIFT FORK AND SHIFT HEAD NO. 2 

    1. Mount the rear case in a vise.
      CAUTION: Be careful not to damage the sealing surface.
    2. Using a pin punch and hammer, drive out the 2 slotted spring pins.
      Fig 10: Driving Out Slotted Spring Pins Using Pin Punch And Hammer
      G02845597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove high and low fork shaft, shift fork and shift gear head No. 2.
      Fig 11: Removing High And Low Fork Shaft, Shift Fork And Shift Gear Head No. 2
      G02845598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      At the time of installation, please refer to the following items.

      • Place the high and low shift fork into the groove of the clutch sleeve.
      • Make sure to install the shift fork and shift gear head No. 2 in the correct direction.

  18. W/O ONE TOUCH 2-4 SELECTOR SYSTEM: 

    REMOVE FRONT DRIVE FORK SHAFT, SHIFT FORK, SPRING AND STOPPER 

    1. Mount the rear case in a vise.
      CAUTION: Be careful not to damage the sealing surface.
    2. Using a pin punch and hammer, drive out the 2 slotted spring pins.
      Fig 12: Driving Out Slotted Spring Pins (3RZ-FE)
      G02845599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 13: Driving Out Slotted Spring Pins (Except 3RZ-FE)
      G02845600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When the pin is removed from the front drive fork shaft, the shaft will spring loose if the pin punch is removed, so keep the pin punch inserted in the shaft hole.

      NOTE:

      At the time of installation, please refer to the following items.

      • Use a pin punch and hammer, drive in the 2 slotted spring pins.
        Fig 14: Driving Slotted Spring Pins (3RZ-FE A\T)
        G02845601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Fig 15: Driving Slotted Spring Pins (EXCEPT - 3RZ-FE A\T )
        G02845602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • When installing the pin in the front drive fork shaft, push the shaft towards the rear case and install the pin while the spring is compressed.
    3. Hold the front drive fork shaft in place by hand, when removing the pin punch.
      Fig 16: Removing Pin Punch
      G02845603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front drive fork shaft, shift fork, spring and stopper.
      Fig 17: Removing Front Drive Fork Shaft, Shift Fork, Spring And Stopper (3RZ-FE A\T)
      G02845604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 18: Removing Front Drive Fork Shaft, Shift Fork, Spring And Stopper (3RZ-FE A\T - Except)
      G02845605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      At the time of installation, please refer to the following items.

      • Place the front drive shift fork into the groove of the clutch sleeve.
      • Make sure to install the shift fork and stopper in the correct direction.
    5. w/o One Touch 2-4 selector system:

      Using a magnetic finger, remove the straight pin.

      Fig 19: Removing Straight Pin Using Magnetic Finger
      G02845606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      At the time of installation, please refer to the following item. Apply gear oil to the straight pin and insert it into the case hole.

  19. w/ One Touch 2-4 selector system: 

    REMOVE REAR OUTPUT SHAFT, DRIVEN SPROCKET, CHAIN AND FRONT DRIVE SHIFT FORK 

    1. Remove the shift fork bolt.
      Fig 20: Removing Shift Fork Bolt
      G02845607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 24 N.m (240 kgf.cm, 17 ft.lbf) 

    2. Using a snap ring expander, remove the snap ring.
      Fig 21: Removing Snap Ring Using Snap Ring Expander
      G02845608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, tap the rear case with pulling the rear output shaft, driven sprocket and front drive shift fork.
      Fig 22: Taping Rear Case With Pulling Rear Output Shaft Using Plastic Hammer
      G02845609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      At the time of installation, please refer to the following items.

      • Place the front drive shift fork into the groove of the clutch sleeve.
      • Make sure to install the shift fork in the correct direction.
      • If necessary, heat the rear case to about 50 - 80°C (122 - 176°F).
    4. Remove the chain.

  20. W/O ONE TOUCH 2-4 SELECTOR SYSTEM: 

    REMOVE HIGH AND LOW FORK SHAFT AND SHIFT FORK 

    Fig 23: Placing Front Drive Shift Fork Into Groove Of Clutch Sleeve (3RZ-FE A\T)
    G02845610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 24: Placing Front Drive Shift Fork Into Groove Of Clutch Sleeve (3RZ-FE A\T - EXCEPT)
    G02845611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    At the time of installation, please refer to the following items.

    • Place the high and low shift fork into the groove of the clutch sleeve.
    • Make sure to install the shift fork in the correct direction.

  21. REMOVE REAR OUTPUT SHAFT, DRIVEN SPROCKET AND CHAIN 
    1. Using a snap ring expander, remove the snap ring.
      Fig 25: Removing Snap Ring Using Snap Ring Expander
      G02845612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, tap the rear case with pulling the rear output shaft and driven sprocket.
      Fig 26: Taping Rear Case With Pulling Rear Output Shaft And Driven Sprocket Using Plastic Hammer
      G02845613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      At the time of installation, please refer to the following item. If necessary, heat the rear case to about 50 - 80°C (122 - 176°F).

    3. Remove the chain.
  22. W/ ONE TOUCH 2-4 SELECTOR SYSTEM: 

    REMOVE ACTUATOR ASSEMBLY 

    1. Using 2 screwdrivers and a hammer, remove the snap ring.
      Fig 27: Removing Snap Ring Using Screwdrivers And Hammer
      G02845614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and the actuator assembly.

      Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

      3. NOTE:

      At the time of installation, please refer to the following item. Coat a new O-ring with gear oil and install it to the actuator assembly.

      Fig 28: Removing O-Ring, 4WD Position Switch And Snap Ring From Actuator Assembly
      G02845615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring, 4WD position switch and snap ring from the actuator assembly.

      Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

  23. M/T: 

    REMOVE SYNCHRONIZER RING FROM INPUT SHAFT 

    Fig 29: Aligning Synchronizer Ring Slots With Shifting Keys
    G02845616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    At the time of installation, please refer to the following items.

    • Apply MP grease to the synchronizer ring.
    • Align the synchronizer ring slots with the shifting keys, and install it on the high and low clutch hub.

  24. REMOVE SEPARATOR WITH OIL STRAINER AND MAGNET 
    Fig 30: Removing Bolts And Oil Pump Body Assembly
    G02845617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Remove the 3 bolts and the separator with the oil strainer and magnet.

    Torque: 7.5 N.m (80 kgf.cm, 69 in.lbf) 

  25. REMOVE OIL PUMP BODY ASSEMBLY 

    Remove the 3 bolts and the oil pump body assembly.

    Torque: 7.5 N.m (80 kgf.cm, 69 in.lbf) 

  26. REMOVE OIL PUMP DRIVE GEAR 
  27. REMOVE PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT 
    1. Using a snap ring expander, remove the snap ring.
      2. Fig 31: Removing Snap Ring Using Snap Ring Expander
      G02845618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull out the planetary gear assembly with the input shaft.
      3. Fig 32: Pulling Planetary Gear Assembly With Input Shaft
      G02845619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    At the time of installation, please refer to the following item. If necessary, heat the front case to about 50 - 80°C (122 - 176°F).

  28. REMOVE LOW GEAR SPLINE PIECE 
      NOTE:

      At the time of installation, please refer to the following item. Be sure the end gap of the snap ring is not aligned with cutout portion of the planetary carrier.

      Fig 33: Removing Snap Ring Using Screwdriver
      G02845620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the snap ring.
    2. Remove the low gear spline piece.
      Fig 34: Removing Low Gear Spline Piece
      G02845621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NEEDLE ROLLER BEARING FROM INPUT SHAFT 
    Fig 35: Applying Gear Oil To Needle Roller Bearing
    G02845622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    At the time of installation, apply gear oil to the needle roller bearing.

  30. REMOVE INPUT SHAFT STOPPER AND THRUST BEARING 
    1. Using a snap ring expander, remove the snap ring.
      Fig 36: Removing Snap Ring Using Snap Ring Expander
      G02845623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      At the time of installation, please refer to the following item. Select a snap ring that will allow 0.05 - 0.15 mm (0.0020 - 0.0059 in.) axial play.

      SNAP RING THICKNESS CHART

      Mark Thickness mm (in.)
      A 2.10 -2.15(0.0827-0.0846)
      B 2.15 -2.20(0.0846-0.0866)
      C 2.20 - 2.25 (0.0866 - 0.0886)
      D 2.25 - 2.30 (0.0886 - 0.0906)
      E 2.30 - 2.35 (0.0906 - 0.0925)
      F 2.35 - 2.40 (0.0925 - 0.0945)
      G 2.40 - 2.45 (0.0945 - 0.0965)
      H 2.45 - 2.50 (0.0965 - 0.0984)
      J 2.50 - 2.55 (0.0984 - 0.1004)
      K 2.55 - 2.60 (0.1004 - 0.1024)
      L 2.60 - 2.65 (0.1024 - 0.1043)
      M 2.65 - 2.70 (0.1043 - 0.1063)
      N 2.70 - 2.75 (0.1063 - 0.1083)
      P 2.75 - 2.80 (0.1083 - 0.1102)
      Q 2.80 - 2.85 (0.1102 - 0.1122)
      R 2.85 - 2.90 (0.1122 - 0.1142)
      S 2.90 - 2.95 (0.1142 - 0.1161)
      T 2.95 - 3.00 (0.1161 - 0.1181)
      U 3.00 - 3.05 (0.1181 - 0.1201)
    2. Remove the input gear stopper, thrust washer and ball.
      Fig 37: Applying Gear Oil To Input Gear Stopper And Thrust Washer
      G02845624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      At the time of installation, apply gear oil to the input gear stopper and thrust washer.

  31. REMOVE INPUT SHAFT, THRUST NEEDLE ROLLER BEARING AND THRUST RACE 
    Fig 38: Removing Input Shaft, Thrust Needle Roller Bearing And Thrust Race
    G02845625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE PLANETARY RING GEAR 
      NOTE:

      At the time of installation, please refer to the following item. Be sure the end gap of the snap ring is not aligned with the upper side of the case.

      Fig 39: Removing Snap Ring Using Screwdriver
      G02845626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the snap ring.
      2. NOTE:

      At the time of installation, apply liquid sealer to the plug.

      Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Fig 40: Removing Plug, Spring And Pin
      G02845627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the plug, spring and pin.

      Torque: 18.6 N.m (190 kgf.cm, 14 ft.lbf) 

      3. NOTE:

      At the time of installation, please refer to the following item. Make sure to install the ring gear in the correct direction.

      Fig 41: Removing Planetary Ring Gear
      G02845628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the planetary ring gear.
  33. INSPECT SWITCHES 

    Check that there is continuity between terminals as shown in SWITCH CONTINUITY CHART .

    Fig 42: Checking Continuity Between Terminals
    G02845629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    SWITCH CONTINUITY CHART

    Switch Position Specified Condition
    Push Continuity
    Free No continuity

    If operation is not as specified, replace the switch.

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