Reassembly

UF1AE TRANSFER: TRANSFER ASSEMBLY: REASSEMBLY

1. INSTALL CENTER DIFFERENTIAL CLUTCH CONTROL VALVE

(a) 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.

(b) While pushing on the center differential control valve plug, install the center differential clutch control valve seat on the transfer upper valve body.

2. INSTALL TRANSFER SOLENOID MODULATOR VALVE

(a) Install the low-high shift valve compression spring, transfer solenoid modulator valve and transfer solenoid modulator valve plug to the transfer upper valve body.

(b) While pushing on the transfer solenoid modulator valve plug, install the transfer solenoid modulator valve plug seat on the transfer upper valve body.

3. INSTALL TRANSFER VALVE BODY COVER

(a) Install the solenoid oil strainer to the transfer valve body cover.

(b) Install the transfer valve body cover and upper transfer valve body plate to the transfer upper valve body.

(c) Install the 6 bolts.

Torque : 6.4 Nm (65 kgf-cm, 57 in-lbf)

HINT

Bolt length:

* Bolt A: 35 mm (1.38 in.)
* Bolt B: 20 mm (0.79 in.)

4. INSTALL TRANSFER CONTROL SOLENOID

(a) Install the transfer control solenoid and solenoid lock plate to the transfer upper valve body with the bolt.

Torque : 6.4 Nm (65 kgf-cm, 57 in-lbf)

HINT
Install the solenoid lock plate into the cutout on the transfer control solenoid.

5. INSTALL TRANSFER DRIVE SPROCKET BEARING

(a) Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket.

SST : 09950-70010

09951-07100

SST : 09950-60010

09951-00640

SST : 09316-20011

(b) Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket.

SST : 09316-60011

09316-00011

NOTICE:
Install the transfer drive sprocket bearing with the shield facing upward.

6. INSTALL TRANSFER DRIVEN SPROCKET BEARING

(a) Using SST and a press, install a new transfer driven sprocket bearing to the transfer front driven clutch sleeve.

SST : 09950-70010

09951-07100

SST : 09950-60010

09951-00640

SST : 09316-20011

(b) Using SST and a press, install a new transfer driven sprocket bearing to the transfer front driven clutch sleeve.

SST : 09316-60011

09316-00011

09316-00041

7. INSTALL TRANSFER CENTER SUPPORT SEAL RING

(a) Coat the 2 seal rings with ATF.

(b) Compress the 2 transfer center support seal rings as shown in the illustration and install them into the grooves on the transfer center support.

NOTICE:
* Do not expand the ring ends excessively.
* If any ring is damaged or deformed, replace it with a new one.

8. INSTALL TRANSFER CENTER SUPPORT

(a) Install the transfer center support to the rear transfer chain case with the 5 bolts.

Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)

(b) Coat 2 new O-rings with ATF.

(c) Install the 2 O-rings to the screws.

(d) Install the 2 gaskets and 2 screws to the rear transfer chain case.

Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)

9. INSTALL TRANSFER DIRECT CLUTCH PISTON O-RING

(a) Coat 2 new O-rings with ATF.

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

O-ring size:

10. INSTALL CENTER DIFFERENTIAL CLUTCH PISTON

(a) Install the center differential clutch piston to the transfer direct clutch drum.

NOTICE:
Do not damage the O-rings.

11. INSTALL TRANSFER DIRECT CLUTCH RETURN SPRING

(a) Install the transfer direct clutch return spring to the transfer direct clutch drum.

12. INSTALL CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER

(a) Coat the rubber on the center differential clutch pressure balancer with ATF.

(b) Install the center differential clutch pressure balancer to the transfer direct clutch drum.

(c) Place SST on the center differential clutch pressure balancer, and compress the return spring with a press.

SST : 09350-30020

09350-07040

(d) Using SST, install the snap ring.

SST : 09350-30020

09350-07040

09350-07070

13. INSTALL CENTER DIFFERENTIAL CLUTCH DISC SET

(a) 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

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.)

NOTICE:
Before assembling new discs, soak them in ATF for at least 15 minutes.

(b) Using a screwdriver with its tip taped, install the snap ring to the transfer direct clutch drum.

(d) Set the dial indicator perpendicular to the flange.

(e) Apply air (200 kpa, 2.0 kgf*cm2, 19 psi) into the oil hole as shown in the illustration. Measure the pack clearance.

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.

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

Flange thickness:

(g) Remove the transfer direct clutch drum from the transfer center support.

14. INSTALL TRANSFER REAR OUTPUT SHAFT BEARING

(a) Install the transfer rear output shaft bearing to the transfer direct clutch drum.

15. INSTALL CENTER DIFFERENTIAL CARRIER

(a) Install the center differential carrier to the transfer rear output shaft and transfer direct clutch drum.

16. INSTALL TRANSFER CASE FRONT OIL SEAL

(a) Using SST and a hammer, install a new oil seal.

SST : 09316-60011

09316-00011

09316-00071

Oil seal installation depth:

5.6 to 6.2 mm (0.220 to 0.244 in.)

(b) Apply MP grease to the oil seal lip.

17. INSTALL TRANSFER CHAIN CASE GOVERNOR APPLY GASKET

(a) Coat 2 new gaskets with ATF.

(b) Install the 2 gaskets to the rear transfer chain case.

(c) Coat a new O-ring and 2 new gaskets with ATF.

(d) Install the O-ring to the screw and install it.

(e) Install the 2 gaskets and screw to the front transfer chain case.

Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)

18. INSTALL TRANSFER BAFFLE VALVE SUB-ASSEMBLY

(a) Install the transfer baffle valve to the rear transfer chain case with the bolt.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

19. INSTALL TRANSFER CASE BEARING

(a) Using SST and a press, install the transfer case bearing to the transfer case.

SST : 09950-60020

09951-00890

SST : 09950-70010

09951-07150

Bearing installation depth:

94.6 to 94.9 mm (3.724 to 3.736 in.)

20. INSTALL TRANSFER CASE REAR OIL SEAL

(a) Using SST and a hammer, install a new oil seal.

SST : 09325-40010

Oil seal installation depth:

2.3 to 2.7 mm (0.091 to 0.106 in.)

(b) Apply MP grease to the oil seal lip.

(c) Install the clamp to the transfer case with the bolt.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

21. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR

(a) Using SST and a press, install a new transfer extension housing dust deflector to the transfer case.

SST : 09950-70010

09951-07150

SST : 09950-60020

09951-00910

22. INSTALL FRONT TRANSFER CHAIN CASE

(a) Remove all residual FIPG material from the contact surfaces using gasoline or alcohol.

(b) Apply seal packing to the front transfer chain case as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(c) Temporarily tighten the 6 bolts in several steps, and then tighten them to the specified torque.

Torque : 34 Nm (345 kgf-cm, 25 ft-lbf)

HINT

Bolt length:

* Bolt A: 57 mm (2.24 in.)
* Bolt B: 74 mm (2.91 in.)
* Other bolts: 45 mm (1.77 in.)

23. INSTALL TRANSFER FRONT DRIVE CHAIN

(a) Install the transfer front drive chain to the transfer drive sprocket and transfer front driven clutch sleeve.

(b) Install the transfer front drive chain, transfer drive sprocket and transfer front drive clutch sleeve.

24. INSTALL REAR TRANSFER CHAIN CASE

(a) Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol.

(b) Apply seal packing to the transfer chain case front as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(c) Temporarily tighten the 10 bolts in several steps, and then tighten to the specified torque.

Bolt (A) - Torque : 57 Nm (580 kgf-cm, 42 ft-lbf)

Except bolt (A) - Torque : 34 Nm (345 kgf-cm, 25 ft-lbf)

HINT

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.)

25. INSTALL FLANGE YOKE

(a) Install the flange yoke.

(b) Using SST, hold the yoke.

SST : 09213-54015

SST : 09330-00021

(c) Using a deep socket wrench (30 mm), torque a new nut.

Torque : 123 Nm (1,250 kgf-cm, 91 ft-lbf)

(d) Using a chisel and hammer, stake the nut.

26. INSTALL TRANSFER REAR OUTPUT SHAFT ASSEMBLY

(a) Install the transfer rear output shaft.

27. INSTALL TRANSFER CASE

(a) Remove all residual FIPG material from the contact surfaces using gasoline or alcohol.

(b) Apply seal packing to the transfer chain case front as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(c) Temporarily tighten the 8 bolts and clamp in several steps, and then tighten them to the specified torque.

Torque : 34 Nm (345 kgf-cm, 25 ft-lbf)

HINT

Bolt length:

* Bolt A: 88 mm (3.46 in.)
* Bolt B: 40 mm (1.57 in.)

28. INSTALL TRANSFER VALVE BODY ASSEMBLY

(a) Coat the transfer wire O-ring with ATF.

(b) Install the transfer wire with the bolt.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(c) Connect the transfer wire connector to the transfer control solenoid.

(d) Install the transfer valve body assembly with the 4 bolts.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

29. INSTALL TRANSFER OIL PAN

(a) Install the transfer oil cleaner magnet to the transfer oil pan.

(b) Remove all residual FIPG material from the contact surfaces using gasoline or alcohol.

(c) Apply seal packing to the transfer chain case front as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(d) Temporarily tighten the 9 bolts in several steps, and then tighten them to the specified torque.

Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)