Reassembly

VF2A TRANSFER: TRANSFER ASSEMBLY: REASSEMBLY

1. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY (for A.D.D. Manual Shift Type)





(a) Apply gear oil to the connecting areas of the clutch sleeve and drive sprocket.

(b) Install the clutch sleeve and 3 shifting keys onto the drive sprocket with the 2 shifting key springs.

NOTICE:
* Install the clutch sleeve in the correct direction.
* Set the key springs so that their openings do not overlap, as shown in the illustration.
* Make sure that the key springs are firmly connected to the shifting keys.
* Make sure that the clutch sleeve and drive sprocket move smoothly.

(c) Apply gear oil to the front drive synchronizer ring's taper cone side.

(d) Install the front drive synchronizer ring.





(e) Apply gear oil to the output shaft and needle roller bearing.

(f) Install the needle roller bearing in the drive sprocket.

(g) Install the drive sprocket (with clutch sleeve).

(h) Install the ball and install the spacer so that it is aligned with the ball.

2. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING

(a) Apply gear oil to the connecting areas of the output shaft and bearing.

(b) 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

3. CHECK TRANSFER DRIVE SPROCKET THRUST CLEARANCE





(a) 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.

4. INSTALL TRANSFER HIGH & LOW CLUTCH SLEEVE





(a) Apply gear oil to the connecting areas of the clutch sleeve and clutch hub.

(b) Install the clutch onto the clutch hub.

NOTICE:
* Install the clutch sleeve in the correct direction.
* Make sure that the clutch sleeve and clutch hub move smoothly.

5. INSTALL TRANSFER OUTPUT SHAFT SHAFT SNAP RING





(a) Select a new snap ring that allows the minimum axial free play.

Standard snap ring thickness:





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

NOTICE:
Make sure that the snap ring is firmly installed into the groove.

6. INSTALL TRANSFER LOW PLANETARY RING GEAR





(a) Install the ring gear onto the case front.

NOTICE:
Install the ring gear in the correct direction.

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





NOTICE:
Make sure that the snap ring is firmly installed into the groove.

7. INSTALL PIN





8. INSTALL COMPRESSION SPRING

9. INSTALL TRANSFER CASE PLUG

(a) Apply sealant to the threads of the plug.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

(b) Install the plug.

Torque : 19 Nm (190 kgf-cm, 14 ft-lbf)

10. INSTALL TRANSFER LOW PLANETARY GEAR BEARING





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

SST : 09950-60010

09951-00570

SST : 09950-70010

09951-00710

Bearing depth:

7.7 to 8.3 mm (0.303 to 0.327 in.)

11. INSTALL TRANSFER INPUT SHAFT BEARING





(a) Using SST and a press, press in a new bearing with the groove facing forward.

SST : 09223-15020

SST : 09515-30010

SST : 09950-70010

09951-07100

12. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING





(a) Select a new snap ring that allows 0.1 mm (0.004 in.) or less of axial free play.

Standard snap ring thickness:





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

NOTICE:
Make sure that the snap ring is firmly installed into the groove.

13. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING





(a) Apply gear oil to the 2 seal rings.

(b) Install the 2 seal rings onto the input shaft.

HINT
Engage the seal rings securely to eliminate clearance, as shown in the illustration.

14. INSTALL TRANSFER LOW PLANETARY GEAR BEARING





(a) Install the bearing onto the low planetary gear.

NOTICE:
Install the bearing in the correct direction.

15. INSTALL NO. 1 TRANSFER THRUST BEARING RACE

(a) Install the bearing race onto the low planetary gear.

16. INSTALL TRANSFER INPUT SHAFT

(a) Apply gear oil to the contact surfaces of the input shaft and low planetary gear.

(b) Install the input shaft onto the low planetary gear.

17. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER





(a) Apply gear oil to the washer.

(b) Install the washer onto the low planetary gear.

18. INSTALL TRANSFER INPUT GEAR STOPPER BALL

(a) Install the ball onto the low planetary gear.

19. INSTALL TRANSFER INPUT GEAR STOPPER

(a) Install the stopper onto the low planetary gear.

20. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING





(a) Select a new snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) of axial free play.

Standard snap ring thickness:





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

NOTICE:
Make sure that the snap ring is firmly installed into the groove.

21. INSTALL TRANSFER CASE OIL SEAL





(a) 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.)

NOTICE:
Be careful not to damage the case front.

(b) Coat the lip of the seal with MP grease.

(c) 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.)

NOTICE:
Be careful not to damage the case front.

(d) Coat the lip of the seal with MP grease.

22. INSTALL FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING





(a) Apply gear oil to the bearing.

(b) Install the bearing onto the low planetary gear.

23. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE





(a) Install the gear spline piece onto the low planetary gear.

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





NOTICE:
Be careful not to damage the gear spline piece.

24. INSTALL TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT





(a) 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).

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





NOTICE:
Make sure that the snap ring is firmly installed into the groove.

25. INSTALL TRANSFER OIL PUMP GEAR





(a) Apply gear oil to the sliding surface of the oil pump gear.

(b) Install the oil pump gear with the nut.

26. INSTALL TRANSFER OIL PUMP BODY O-RING





(a) Coat a new O-ring with gear oil and install it onto the pump body.

27. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY





(a) Install the oil pump body with the 3 bolts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

28. INSTALL TRANSFER CASE MAGNET





29. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY

(a) Install the oil separator with the 3 bolts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

30. INSTALL NO. 1 TRANSFER CASE PLUG (for Filler)

(a) Install a new gasket and the filler plug.

Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)

31. INSTALL NO. 1 TRANSFER CASE PLUG (for Drain)

(a) Install a new gasket and the drain plug.

Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)

32. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING





(a) Apply gear oil to the contact surfaces of the bearing and driven sprocket.

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

SST : 09316-60011

09316-00031

NOTICE:
After press-fitting the bearing to the driven sprocket, check that the bearing moves smoothly.

33. INSTALL TRANSFER DRIVEN SPROCKET BEARING





(a) Apply gear oil to the contact surfaces of the bearing and driven sprocket.

(b) Using a press, press in a new bearing.

NOTICE:
After press-fitting the bearing to the driven sprocket, check that the bearing moves smoothly.

34. INSTALL REAR TRANSFER OUTPUT SHAFT, TRANSFER FRONT DRIVE CHAIN AND TRANSFER DRIVEN SPROCKET





(a) Mount the rear case in a vise.

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

(b) Install the output shaft and driven sprocket onto the front drive chain.

(c) Install the output shaft, front drive chain and driven sprocket onto the rear case.

NOTICE:
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).

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





NOTICE:
Make sure that the snap ring is firmly installed into the groove.

35. INSTALL TRANSFER HIGH AND LOW SHIFT FORK SHAFT





(a) Apply gear oil to the connecting areas of the shift fork shaft and each part.

(b) Install the shift fork shaft and No. 2 gear shift fork.

NOTICE:
Install the shift fork shaft and No. 2 gear shift fork in the correct directions.

(c) Install the spring and ball into the hole.

(d) Apply sealant to the threads of the plug.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

(e) Using a hexagon wrench, install the plug.

Torque : 19 Nm (190 kgf-cm, 14 ft-lbf)

36. INSTALL FRONT TRANSFER DRIVE SHIFT FORK SHAFT





(a) Apply gear oil to the straight pin.

(b) Install the straight pin into the hole.

(c) Apply gear oil to the connecting areas of the shift fork shaft and each part.





(d) Install the shift fork shaft, No. 1 gear shift fork, spring and shift shaft stopper.

NOTICE:
Install the shift fork shaft, No. 1 gear shift fork and shift shaft stopper in the correct directions.

(e) Using a pin punch and hammer, install the 2 slotted pins.





NOTICE:
When installing the slotted pins, make sure that groove A of the pin is facing in the same direction as the shaft.

(f) Install the spring and ball into the hole.

(g) Apply sealant to the threads of the plug.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

(h) Using a hexagon wrench, install the plug.

Torque : 19 Nm (190 kgf-cm, 14 ft-lbf)

37. INSTALL REAR TRANSFER CASE





(a) Apply FIPG to the rear case as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

NOTICE:
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.

(b) Install the clamp and rear case with the 12 bolts.





Torque : 28 Nm (285 kgf-cm, 21 ft-lbf)

NOTICE:
Tighten the bolts of the rear case within 10 minutes of applying the FIPG. The FIPG will dry very quickly.

38. INSTALL TRANSFER OUTPUT SHAFT WASHER

(a) Install the 2 output washers.

39. INSTALL TRANSFER COVER OIL SEAL





(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the housing upper surface.

SST : 09223-46011

SST : 09631-32020

NOTICE:
Be careful not to damage the extension housing.

(b) Coat the lip of the oil seal with MP grease.

40. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY





(a) Apply FIPG to the extension housing as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

NOTICE:
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.

(b) Apply sealant to the threads of the bolts.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

(c) Install the extension housing with the 5 bolts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

NOTICE:
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

(a) 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)





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

SST : 09950-60010

09951-00320

SST : 09950-70010

09951-07100

NOTICE:
Be careful not to damage the companion flange.

43. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (for Rear)

(a) 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

SST : 09950-70010

09951-07100

NOTICE:
Be careful not to damage the companion flange.

44. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Front)





(a) Apply gear oil to the connecting areas of the companion flange and driven sprocket.

(b) Install the companion flange onto the driven sprocket.

(c) Using SST to hold the companion flange, install a new lock nut.

SST : 09330-00021

SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04051

09957-04010

09958-04011

Torque : 118 Nm (1,203 kgf-cm, 87 ft-lbf)

(d) Using a chisel and hammer, stake the lock nut to the driven sprocket.





NOTICE:
* 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.

45. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Rear)

(a) Apply gear oil to the connecting areas of the companion flange and output shaft.

(b) Using SST, install the companion flange (rear) in the same way as the companion flange (front).

SST : 09330-00021

SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04051

09957-04010

09958-04011

Torque : 118 Nm (1,203 kgf-cm, 87 ft-lbf)

46. INSTALL BREATHER OIL DEFLECTOR SUB-ASSEMBLY

47. INSTALL TRANSFER CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY





(a) Install the retainer with the 4 bolts.

Torque : 18 Nm (183 kgf-cm, 13 ft-lbf)

48. INSTALL TRANSFER COVER OIL SEAL





(a) 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

SST : 09950-70010

09951-07100

NOTICE:
Be careful not to damage the bearing retainer.

(b) Coat the lip of the oil seal with MP grease.

49. INSTALL TRANSFER BEARING RETAINER SUB-ASSEMBLY





(a) Apply FIPG to the bearing retainer as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

NOTICE:
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.

(b) Apply sealant to the bolt threads.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

(c) Install the retainer with the 5 bolts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

NOTICE:
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





(a) Install new gaskets and the indicator switches.

Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)

HINT
Indicator switch: