Reassembly

JF1A TRANSFER: TRANSFER ASSEMBLY:

REASSEMBLY

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL TRANSFER DRIVE CLUTCH HUB

(a) Using SST and a press, press in the drive clutch hub.
SST: 09513-36040
2. INSTALL FRONT DRIVE CLUTCH SLEEVE
(a) Apply gear oil to the connecting areas of the clutch sleeve and clutch hub.

(b) Install the drive clutch sleeve onto the rear output shaft.

NOTE: Make sure that the clutch sleeve is installed facing the correct direction.

(c) Install the 3 No. 1 synchromesh shifting keys and 2 No. 1 synchromesh shifting key springs.

NOTE: Install the key springs so that their end gaps are not aligned.

3. INSTALL TRANSFER SYNCHRONIZER RING SET

(a) Install the outer synchronizer ring onto the rear output shaft.

NOTE: Align the slots of the outer synchronizer ring with the shifting keys.

(b) Install the center synchronizer ring onto the rear output shaft.

(c) Install the inner synchronizer rings onto the rear output shaft.

NOTE: Align the slots of the outer synchronizer ring with those of the inner rings.

4. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

(a) Install a new drive sprocket bearing.

(b) Install the drive sprocket.

NOTE: Align the cutouts in the drive sprocket with the protrusions on the center synchronizer ring.

5. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING

(a) Using SST and a press, press in a new bearing.

NOTE: Make sure the bearing is installed in the correct direction.

SST: 09316-60011
09316-00011
6. INSPECT TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

(a) Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance:
0.10 to 0.26 mm (0.00394 to 0.0102 in.)
Maximum clearance:
0.26 mm (0.0102 in.)
If the clearance is greater than the maximum, replace the drive sprocket sub-assembly.
7. INSTALL TRANSFER CLUTCH HUB

(a) Using SST and a press, press in the clutch hub.
SST: 09316-60011
09316-00011

(b) Select a snap ring that allows for minimum axial play and install it to the shaft.
Snap ring thickness:

(c) Using a snap ring expander, install the snap ring.

NOTE: Make sure that the snap ring is firmly installed to the groove.

8. INSTALL TRANSFER HIGH AND LOW CLUTCH SLEEVE

(a) Install the high and low clutch sleeve onto the clutch hub.

NOTE: Make sure that the high and low clutch sleeve is installed facing the correct direction.

9. INSTALL TRANSFER SYNCHROMESH SHIFTING KEY SPRING

(a) Install the synchromesh shifting key and synchromesh shifting key spring as shown in the illustration.

(b) Using a snap ring expander, install the snap ring.

NOTE: Make sure that the snap ring is firmly installed to the groove.

10. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER

(a) Install the washer, low planetary gear bearing and output shaft spacer to the output shaft.

(b) Using a snap ring expander, install the snap ring.

NOTE: Make sure that the snap ring is firmly installed to the groove.

11. INSTALL TRANSFER CASE FRONT OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal until its surface is 1 to 1.5 mm (0.0394 to 0.0591 in.) from the front case upper surface.
SST: 09950-60020
09951-00720
SST: 09950-70010
09951-07100

NOTE: Be careful not to damage the front case.

(b) Coat the lip of the oil seal with MP grease.
12. INSTALL TRANSFER DRIVEN SPROCKET BEARING

(a) Install the bearing to the front case in the direction shown in the illustration.

NOTE: Make sure the bearing is installed in the correct direction.

(b) Using a screwdriver, install the snap ring.
13. INSTALL TRANSFER LOW PLANETARY RING GEAR

(a) Install the ring gear to the transfer front case.

NOTE: Make sure to install the ring gear in the correct direction.

(b) Using a screwdriver, install the snap ring.

NOTE: Make sure that the snap ring is firmly installed to the groove.

14. INSTALL TRANSFER INPUT SHAFT PLUG

(a) Using SST and a hammer, tap in a new input shaft plug.
SST: 09316-60011
09316-00011

NOTE: Be careful not to damage or deform the input shaft plug when tapping it.

15. INSTALL TRANSFER LOW PLANETARY GEAR ASSEMBLY

(a) Install the low planetary gear bearing and low planetary gear to the input shaft.

NOTE: Make sure the low planetary gear bearing is installed in the correct direction.

(b) Using a screwdriver, install the low planetary gear spline piece.

NOTE: Make sure that the end gap of the snap ring is not aligned with the cutout of the planetary carrier.

16. INSTALL TRANSFER INPUT SHAFT BEARING

(a) Install the input shaft bearing and low planetary gear bearing to the input shaft.

- Make sure the input shaft bearing are installed in the correct direction.
- Make sure that the temper color side of the low planetary gear bearing faces downward.

(b) Using SST and a press, press in a new bearing.
SST: 09513-36040

NOTE: After press-fitting the bearing to the input shaft, check that the bearing moves smoothly.

(d) Using a snap ring expander, install the snap ring.

NOTE: Make sure that the snap ring is firmly installed to the groove.

17. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING

(a) Install a new seal ring to the input shaft.
18. INSTALL TRANSFER OIL SEAL RING

(a) Install a new seal ring to the input shaft.
19. INSTALL INPUT SHAFT ASSEMBLY

(a) Install the snap ring to the front case.

(b) While expanding the snap ring, install the input shaft to the front case.
(c) Apply adhesive to the threads of the 2 plugs.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(d) Install the 2 plugs.
Torque: 37 Nm (377 kgf-cm, 27 ft-lbf)
20. INSTALL TRANSFER CASE MAGNET
21. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY

(a) Install the oil separator with the 3 bolts.
Torque: 17 Nm (178 kgf-cm, 13 ft-lbf)
22. INSTALL TRANSFER CASE REAR OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear case upper surface.
SST: 09950-60020
09951-00710
SST: 09950-70010
09951-07100

NOTE: Be careful not to damage the rear case.

(b) Coat the lip of the oil seal with MP grease.
23. INSTALL SIDE GEAR SHAFT HOLDER BEARING
(a) Install the side gear shaft holder bearing to the rear case.

(b) Using a screwdriver, install the snap ring.
24. INSTALL REAR OUTPUT SHAFT
(a) Install the snap ring to the rear case.
(b) Mount the rear case in a vise.

NOTE: Place aluminum plates on the vise to prevent damage to the rear case.

(d) Install the rear output shaft , front drive chain and driven sprocket.

NOTE: Do not drop the clutch sleeve or shifting key.

(e) Using a snap ring expander, install the snap ring.

NOTE: Make sure that the snap ring is firmly installed to the groove.

25. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY

(a) Install a new O-ring to the shift actuator.

(b) Set the No. 1 gear shift fork and No. 2 gear shift fork to the rear case. Then install the shift actuator to the rear case with the 3 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
26. INSTALL NO. 1 TRANSFER GEAR SHIFT FORK

(a) Install the No. 1 gear shift fork to the shift actuator with the bolt.
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
27. INSTALL NO. 2 TRANSFER GEAR SHIFT FORK

(a) Install the No. 2 gear shift fork to the shift actuator with the bolt.
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)

(b) Using a screwdriver and hammer, tap the 3 shift fork shaft snap rings into the shift fork shaft.
28. INSTALL REAR TRANSFER CASE

(a) Install the output shaft front needle roller bearing and No. 3 synchronizer ring outer to the output shaft.

(b) Apply seal packing to the rear case as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or 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 seal packing to the rear case.

(c) Install the rear case with the 14 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)

NOTE: Tighten the bolts of the rear case within 10 minutes of applying the seal packing. The seal packing will dry very quickly.

29. INSTALL TRANSFER CASE PLUG
(a) Apply adhesive to the threads of the plug.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Install the plug.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
30. INSTALL NO. 1 TRANSFER CASE PLUG

(a) Install the pin and compression spring to the front case.
(b) Apply adhesive to the threads of the plug.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(c) Install the plug.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
(d) Apply adhesive to the threads of the plug.
31. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
(a) Install the companion flange sub-assembly onto the drive sprocket sub-assembly.

(b) Using SST to hold the companion flange, install a new companion flange lock nut.
SST: 09330-00021
Torque: 127 Nm (1299 kgf-cm, 94 ft-lbf)

(c) Using a chisel and hammer, stake the companion flange lock nut.
32. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
(a) Install the companion flange onto the output shaft.

(b) Using SST to hold the companion flange, install a new companion flange lock nut.
SST: 09330-00021
Torque: 127 Nm (1299 kgf-cm, 94 ft-lbf)

(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump plate upper surface.
SST: 09950-60010
09951-00680
SST: 09950-70010
09951-07100

NOTE: Be careful not to damage the oil pump plate.

34. INSTALL TRANSFER CASE PLUG

(a) Install the relief valve seat, ball and compression ring to the oil pump plate.
(b) Apply adhesive to the threads of the plug.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(c) Using a 10 mm hexagon wrench, install the plug.
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)
35. INSTALL TRANSFER CASE STRAIGHT PIN

(a) Install the straight pin to the input shaft.
36. INSTALL TRANSFER OIL PUMP PLATE
(a) Apply transfer oil to a new O-ring, drive rotor and driven rotor.

(b) Install the O-ring, drive rotor and driven rotor to the oil pump plate.