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Transfer Assembly: Reassembly

  1. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY (for A.D.D. Manual Shift Type) 
    1. Apply gear oil to the connecting areas of the clutch sleeve and drive sprocket.
    2. Install the clutch sleeve and 3 shifting keys onto the drive sprocket with the 2 shifting key springs.
      NOTE:
      • Install the clutch sleeve in the correct direction.
      • Set the key springs so that their openings do not overlap, as shown in Fig 1.
      • Make sure that the key springs are firmly connected to the shifting keys.
      • Make sure that the clutch sleeve and drive sprocket move smoothly.
      Fig 1: Identifying Clutch Sleeve & Shifting Keys
      G05111473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply gear oil to the front drive synchronizer ring's taper cone side.
    4. Install the front drive synchronizer ring.
    5. Apply gear oil to the output shaft and needle roller bearing.
    6. Install the needle roller bearing in the drive sprocket.
    7. Install the drive sprocket (with clutch sleeve).
    8. Install the ball and install the spacer so that it is aligned with the ball.
      Fig 2: Identifying Transfer Drive Sprocket Sub-Assembly (For A.D.D. Manual Shift Type)
      G05111463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING 
    1. Apply gear oil to the connecting areas of the output shaft and bearing.
    2. Using SST and a press, press in a new bearing with the outer race snap ring groove facing toward the rear.

      SST 09316-60011 (09316-00011, 09316-00071) 

      Fig 3: Pressing In Rear Transfer Output Shaft Radial Ball Bearing Using SST & Press
      G05111475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CHECK TRANSFER DRIVE SPROCKET THRUST CLEARANCE 
    1. Using a feeler gauge, measure the thrust clearance.

      Standard thrust clearance: 0.10 to 0.25 mm (0.0039 to 0.0098 in.) 

      Maximum thrust clearance: 0.25 mm (0.0098 in.) 

      If the thrust clearance is greater than the maximum, replace the drive sprocket.

      Fig 4: Measuring Thrust Clearance Using Feeler Gauge
      G05111468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL TRANSFER HIGH AND LOW CLUTCH SLEEVE 
    1. Apply gear oil to the connecting areas of the clutch sleeve and clutch hub.
    2. Install the clutch onto the clutch hub.
      NOTE:
      • Install the clutch sleeve in the correct direction.
      • Make sure that the clutch sleeve and clutch hub move smoothly.
        Fig 5: Identifying Clutch Sleeve & Hub
        G05111477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL TRANSFER OUTPUT SHAFT SNAP RING 
    1. Select a new snap ring that allows the minimum axial free play.
      Fig 6: Identifying Transfer Output Shaft Snap Ring
      G05111478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS

      Mark Specified Condition
      K 2.00 to 2.05 mm (0.0787 to 0.0807 in.)
      L 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
      A 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      B 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
      C 2.20 to 2.25 mm (0.0866 to 0.0886 in.)
      D 2.25 to 2.30 mm (0.0886 to 0.0906 in.)
      E 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      F 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
      G 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
      H 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      J 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
    2. Using a snap ring expander, install the snap ring.
      NOTE: Make sure that the snap ring is firmly installed into the groove.
  6. INSTALL TRANSFER LOW PLANETARY RING GEAR 
    1. Install the ring gear onto the case front.
      NOTE: Install the ring gear in the correct direction.
      Fig 7: Identifying Low Planetary Ring Gear
      G04963864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring.
      NOTE: Make sure that the snap ring is firmly installed into the groove.
      Fig 8: Identifying Snap Ring & Screwdriver
      G04963863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL PIN 
    Fig 9: Identifying Pin
    G05111451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL COMPRESSION SPRING 
  9. INSTALL TRANSFER CASE PLUG 
    1. Apply sealant to the threads of the plug.

      Sealant: 

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

    2. Install the plug.

      Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) 

  10. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    1. Using SST and a press, press in a new bearing.

      SST 09950-60010 (09951-00570), 09950-70010 (09951-00710) 

      Bearing depth: 7.7 to 8.3 mm (0.303 to 0.327 in.) 

      Fig 10: Pressing In Transfer Low Planetary Gear Bearing Using SST & Press
      G05111482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL TRANSFER INPUT SHAFT BEARING 
    1. Using SST and a press, press in a new bearing with the groove facing forward.

      SST 09223-15020, 09515-30010, 09950-70010 (09951-07100) 

      Fig 11: Pressing In Transfer Input Shaft Bearing Using SST & Press
      G05111483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING 
    1. Select a new snap ring that allows 0.1 mm (0.004 in.) or less of axial free play.

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS

      Mark Specified Condition
      1 1.45 to 1.50 mm (0.0571 to 0.0591 in.)
      2 1.50 to 1.55 mm (0.0591 to 0.0610 in.)
      3 1.55 to 1.60 mm (0.0610 to 0.0630 in.)
      4 1.60 to 1.65 mm (0.0630 to 0.0650 in.)
      5 1.65 to 1.70 mm (0.0650 to 0.0669 in.)
      Fig 12: Identifying Transfer Input Bearing Shaft Snap Ring
      G05111484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install the snap ring.
      NOTE: Make sure that the snap ring is firmly installed into the groove.
  13. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING 
    1. Apply gear oil to the 2 seal rings.
    2. Install the 2 seal rings onto the input shaft.

      HINT:

      Engage the seal rings securely to eliminate clearance.

      Fig 13: Identifying No. 1 Transfer Input Shaft Seal Rings
      G05111459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL TRANSFER LOW PLANETARY GEAR BEARING 
    1. Install the bearing onto the low planetary gear.
      NOTE: Install the bearing in the correct direction.
      Fig 14: Identifying Transfer Low Planetary Gear Bearing
      G05111486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL NO. 1 TRANSFER THRUST BEARING RACE 
    1. Install the bearing race onto the low planetary gear.
  16. INSTALL TRANSFER INPUT SHAFT 
    1. Apply gear oil to the contact surfaces of the input shaft and low planetary gear.
    2. Install the input shaft onto the low planetary gear.
  17. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER 
    1. Apply gear oil to the washer.
    2. Install the washer onto the low planetary gear.
    Fig 15: Identifying Manual Transfer Planetary Carrier Washer
    G05111487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL TRANSFER INPUT GEAR STOPPER BALL 
    1. Install the ball onto the low planetary gear.
  19. INSTALL TRANSFER INPUT GEAR STOPPER 
    1. Install the stopper onto the low planetary gear.
  20. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING 
    1. Select a new snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) of axial free play.
      Fig 16: Identifying Input Gear Stopper Shaft Snap Ring
      G04963892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard snap ring thickness 

      STANDARD SNAP RING THICKNESS

      Mark Specified Condition
      A 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      B 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
      C 2.20 to 2.25 mm (0.0866 to 0.0886 in.)
      D 2.25 to 2.30 mm (0.0886 to 0.0906 in.)
      E 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      F 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
      G 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
      H 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      J 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
      K 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
      L 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
      M 2.65 to 2.70 mm (0.1043 to 0.1063 in.)
      N 2.70 to 2.75 mm (0.1063 to 0.1083 in.)
      P 2.75 to 2.80 mm (0.1083 to 0.1102 in.)
      Q 2.80 to 2.85 mm (0.1102 to 0.1122 in.)
      R 2.85 to 2.90 mm (0.1122 to 0.1142 in.)
      S 2.90 to 2.95 mm (0.1142 to 0.1161 in.)
      T 2.95 to 3.00 mm (0.1161 to 0.1181 in.)
      U 3.00 to 3.05 mm (0.1181 to 0.1201 in.)
    2. Using a snap ring expander, install the snap ring.
      NOTE: Make sure that the snap ring is firmly installed into the groove.
  21. INSTALL TRANSFER CASE OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 1)

      SST 09316-60011 

      Oil seal depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) 

      NOTE: Be careful not to damage the case front.
      Fig 17: Tapping In Transfer Case Oil Seal Using SST & Hammer (1 Of 2)
      G05111489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the lip of the seal with MP grease.
    3. Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 2).

      SST 09316-60011 

      Oil seal depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) 

      NOTE: Be careful not to damage the case front.
      Fig 18: Tapping In Transfer Case Oil Seal Using SST & Hammer (2 Of 2)
      G05111490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the lip of the seal with MP grease.
  22. INSTALL FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING 
    1. Apply gear oil to the bearing.
    2. Install the bearing onto the low planetary gear.
      Fig 19: Identifying Front Transfer Output Shaft Needle Roller Bearing & Low Planetary Gear
      G05111455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE 
    1. Install the gear spline piece onto the low planetary gear.
      Fig 20: Identifying Gear Spline Piece & Low Planetary Gear
      G05111454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring.
      NOTE: Be careful not to damage the gear spline piece.
      Fig 21: Identifying Snap Ring & Screwdriver
      G05111453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT 
    1. Install the low planetary gear with input shaft.

      HINT:

      If necessary, heat the case front to about 50 to 80°C (122 to 176°F).

      Fig 22: Identifying Low Planetary Gear With Input Shaft
      G05111450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install the snap ring.
      NOTE: Make sure that the snap ring is firmly installed into the groove.
      Fig 23: Identifying Snap Ring & Expander
      G04963835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL TRANSFER OIL PUMP GEAR 
    1. Apply gear oil to the sliding surface of the oil pump gear.
    2. Install the oil pump gear with the nut.
      Fig 24: Identifying Transfer Oil Pump Gear
      G04963834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL TRANSFER OIL PUMP BODY O-RING 
    1. Coat a new O-ring with gear oil and install it onto the pump body.
      Fig 25: Identifying Transfer Oil Pump Body O-Ring
      G05111497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY 
    1. Install the oil pump body with the 3 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 26: Identifying Oil Pump Body With Bolts
      G05111446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL TRANSFER CASE MAGNET 
  29. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY 
    1. Install the oil separator with the 3 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 27: Identifying Oil Separator Sub-Assembly Bolts
      G04963831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL NO. 1 TRANSFER CASE PLUG (for Filler) 
    1. Install a new gasket and the filler plug.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

  31. INSTALL NO. 1 TRANSFER CASE PLUG (for Drain) 
    1. Install a new gasket and the drain plug.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

  32. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING 
    1. Apply gear oil to the contact surfaces of the bearing and driven sprocket.
    2. Using SST and a press, press in a new bearing.

      SST 09316-60011 (09316-00031) 

      NOTE: After press-fitting the bearing to the driven sprocket, check that the bearing moves smoothly.
      Fig 28: Pressing In Transfer Input Gear Radial Ball Bearing Using SST & Press
      G05111500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL TRANSFER DRIVEN SPROCKET BEARING 
    1. Apply gear oil to the contact surfaces of the bearing and driven sprocket.
    2. Using a press, press in a new bearing.
      NOTE: After press-fitting the bearing to the driven sprocket, check that the bearing moves smoothly.
      Fig 29: Pressing In Transfer Driven Sprocket Bearing Using Press
      G04963903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL REAR TRANSFER OUTPUT SHAFT, TRANSFER FRONT DRIVE CHAIN AND TRANSFER DRIVEN SPROCKET 
    1. Mount the rear case in a vise.
      NOTE: Place aluminum plates on the vise to prevent damage to the rear case.
    2. Install the output shaft and driven sprocket onto the front drive chain.
      Fig 30: Identifying Output Shaft & Driven Sprocket With Front Drive Chain
      G05111502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the output shaft, front drive chain and driven sprocket onto the rear case.
      NOTE: When installing the output shaft, make sure that the installation of the synchronizer ring, sleeve and shifting keys are not affected.

      HINT:

      Check that the output shaft and driven sprocket turn smoothly.

      If necessary, heat the rear case to approximately 50 to 80°C (122 to 176°F).

    4. Using a snap ring expander, install the snap ring.
      NOTE: Make sure that the snap ring is firmly installed into the groove.
      Fig 31: Identifying Snap Ring
      G05111441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL TRANSFER HIGH AND LOW SHIFT FORK SHAFT 
    1. Apply gear oil to the connecting areas of the shift fork shaft and each part.
    2. Install the shift fork shaft and No. 2 gear shift fork.
      NOTE: Install the shift fork shaft and No. 2 gear shift fork in the correct directions.
      Fig 32: Identifying Shift Fork Shaft & No. 2 Gear Shift Fork
      G05111440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the spring and ball into the hole.
    4. Apply sealant to the threads of the plug.

      Sealant: 

      Part No. 08833-00083, THREE BOND 1344, LOCTITE 242 or the equivalent 

    5. Using a hexagon wrench, install the plug.

      Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) 

  36. INSTALL FRONT TRANSFER DRIVE SHIFT FORK SHAFT 
    1. Apply gear oil to the straight pin.
    2. Install the straight pin into the hole.
      Fig 33: Identifying Straight Pin
      G05111439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply gear oil to the connecting areas of the shift fork shaft and each part.
    4. Install the shift fork shaft, No. 1 gear shift fork, spring and shift shaft stopper.
      NOTE: Install the shift fork shaft, No. 1 gear shift fork and shift shaft stopper in the correct directions.
      Fig 34: Identifying Shift Fork Shaft, No. 1 Gear Shift Fork & Shift Shaft Stopper
      G05111438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a pin punch and hammer, install the 2 slotted pins.
      NOTE: When installing the slotted pins, make sure that groove A of the pin is facing in the same direction as the shaft.
      Fig 35: Installing Slotted Pins
      G05111507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the spring and ball into the hole.
    7. Apply sealant to the threads of the plug.

      Sealant: 

      Part No. 08833-00083, THREE BOND 1344, LOCTITE 242 or the equivalent 

    8. Using a hexagon wrench, install the plug.

      Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) 

  37. INSTALL REAR TRANSFER CASE 
    1. Apply FIPG to the rear case.

      FIPG: 

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

      NOTE: If the removed rear case will be reused:
      After removing the rear case, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old FIPG on the rear case's contact surface, 2) clean off any remaining old FIPG from the rear case's contact surface, and 3) reapply FIPG to the rear case.
      Fig 36: Applying FIPG To Rear Case
      G05111508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the clamp and rear case with the 12 bolts.

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

      NOTE: Tighten the bolts of the rear case within 10 minutes of applying the FIPG. The FIPG will dry very quickly.
      Fig 37: Identifying Clamp & Rear Case With Bolts
      G05111434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL TRANSFER OUTPUT WASHER 
    1. Install the 2 output washers.
  39. INSTALL TRANSFER COVER OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the housing upper surface.

      SST 09223-46011, 09631-32020 

      NOTE: Be careful not to damage the extension housing.
    2. Coat the lip of the oil seal with MP grease.
      Fig 38: Tapping In Oil Seal Using SST & Hammer
      G05111510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 
    1. Apply FIPG to the extension housing.

      FIPG: 

      THREE BOND 1281 or the equivalent 

      NOTE: If the removed extension housing will be reused:
      After removing the housing, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old FIPG on the housing's contact surface, 2) clean off any remaining old FIPG from the housing's contact surface, and 3) reapply FIPG to the housing.
      Fig 39: Identifying FIPG Grease Applying Area
      G04963917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply sealant to the threads of the bolts.

      Sealant: 

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

    3. Install the extension housing with the 5 bolts.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      NOTE: Tighten the bolts of the extension housing within 10 minutes of applying the FIPG. The FIPG will dry very quickly.
  41. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Install the O-ring and speedometer driven hole cover sub-assembly with the bolt.
  42. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (for Front) 
    1. Using SST and a hammer, tap in a new oil seal.

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      NOTE: Be careful not to damage the companion flange.
      Fig 40: Tapping In New Oil Seal Using SST & Hammer
      G05111512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (for Rear) 
    1. Using SST and a hammer, tap in a new oil seal (for rear) in the same way as the oil seal (for front).

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      NOTE: Be careful not to damage the companion flange.
  44. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Front) 
    1. Apply gear oil to the connecting areas of the companion flange and driven sprocket.
    2. Install the companion flange onto the driven sprocket.
    3. Using SST to hold the companion flange, install a new lock nut.

      SST 09330-00021, 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) 

      Torque: 118 N*m (1,203 kgf*cm, 87 ft.*lbf) 

      Fig 41: Installing Lock Nut Using SST
      G05111513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a chisel and hammer, stake the lock nut to the driven sprocket.
      NOTE:
      • Securely stake the shaft to the lock nut's groove.
      • Be careful not to damage parts around the lock nut.
      • Do not apply excessive force to the shaft.
        Fig 42: Staking Lock Nut To Driven Sprocket Using Chisel & Hammer
        G05111514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Rear) 
    1. Apply gear oil to the connecting areas of the companion flange and output shaft.
    2. Using SST, install the companion flange (rear) in the same way as the companion flange (front).

      SST 09330-00021, 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) 

      Torque: 118 N*m (1,203 kgf*cm, 87 ft.*lbf) 

  46. INSTALL BREATHER OIL DEFLECTOR SUB-ASSEMBLY 
  47. INSTALL TRANSFER CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY 
    1. Install the retainer with the 4 bolts.

      Torque: 18 N*m (183 kgf*cm, 13 ft.*lbf) 

      Fig 43: Identifying Retainer Bolts
      G05111430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL TRANSFER COVER OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the bearing retainer upper surface.

      SST 09950-60010 (09951-00590), 09950-70010 (09951-07100) 

      NOTE: Be careful not to damage the bearing retainer.
    2. Coat the lip of the oil seal with MP grease.
      Fig 44: Tapping In New Oil Seal
      G05111510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL TRANSFER BEARING RETAINER SUB-ASSEMBLY 
    1. Apply FIPG to the bearing retainer.

      FIPG: 

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

      NOTE: If the removed bearing retainer will be reused:
      After removing the retainer, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old FIPG on the retainer's contact surface, 2) clean off any remaining old FIPG from the retainer's contact surface, and 3) reapply FIPG to the retainer.
      Fig 45: Identifying FIPG Grease Applying Area
      G04963923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply sealant to the bolt threads.

      Sealant: 

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

    3. Install the retainer with the 5 bolts.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      NOTE: Tighten the bolts of the bearing retainer within 10 minutes of applying the FIPG. The FIPG will dry very quickly.
  50. INSTALL TRANSFER INDICATOR SWITCH 
    1. Install new gaskets and the indicator switches.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

      Fig 46: Identifying New Gaskets & Indicator Switches
      G05111429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Indicator switch:

      TRANSFER INDICATOR SWITCH

      No. 1 Indicator switch (neutral position)
      No. 2 Indicator switch (L4 position)
      No. 3 Indicator switch (4WD position)
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