Reassembly
VF4B TRANSFER: TRANSFER ASSEMBLY: REASSEMBLY
1. INSTALL TRANSFER LOW PLANETARY RING GEAR
(a) Install the ring gear onto the front case.
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.
2. INSTALL TRANSFER CASE STRAIGHT PIN
3. INSTALL COMPRESSION SPRING
4. 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 case plug.
Torque : 19 Nm (190 kgf-cm, 14 ft-lbf)
5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER
6. INSTALL TRANSFER DRIVE SPROCKET BEARING
7. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER
9. 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
10. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER
11. INSTALL FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING
12. INSTALL TRANSFER CLUTCH HUB
13. INSTALL CENTER DIFFERENTIAL CASE
14. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL
15. INSTALL NO. 2 TRANSFER OUTPUT SHAFT SPACER
16. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING
(a) Using a snap ring expander, install the snap ring.
NOTICE:
Make sure that the snap ring is firmly installed into the groove.
17. INSPECT TRANSFER DRIVE SPROCKET RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance of the drive sprocket.
Standard clearance:
0.01 to 0.06 mm (0.0004 to 0.0024 in.)
Maximum clearance:
0.06 mm (0.0024 in.)
If the clearance is greater than the maximum, replace the drive sprocket, output shaft or needle roller bearing.
18. INSPECT TRANSFER DRIVE SPROCKET THRUST CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance of the drive sprocket.
Standard clearance:
0.15 to 0.24 mm (0.0059 to 0.0094 in.)
Maximum clearance:
0.24 mm (0.0094 in.)
If the clearance is greater than the maximum, replace the drive sprocket.
19. 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
09951-07100
Standard depth:
7.7 to 8.3 mm (0.303 to 0.327 in.)
20. 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
21. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE
(a) Using a screwdriver, install the spline piece and low planetary gear with the snap ring.
NOTICE:
* Be careful not to damage the spline piece.
* Make sure that the snap ring is firmly installed into the groove.
22. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING
(a) Select a new snap ring that allows 0.1 mm (0.0039 in.) or less of axial free play.
Standard snap ring thickness:
NOTICE:
Make sure that the snap ring is firmly installed into the groove.
(b) Using a snap ring expander, install the snap ring.
23. 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.
24. INSTALL TRANSFER LOW PLANETARY GEAR BEARING
(a) Install the bearing onto the low planetary gear.
NOTICE:
Install the bearing in the correct direction.
25. INSTALL NO. 1 TRANSFER THRUST BEARING RACE
26. INSTALL TRANSFER INPUT SHAFT
(a) Apply gear oil to the contact surface of the input shaft and low planetary gear.
(b) Install the input shaft onto the low planetary gear.
27. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER
(a) Apply gear oil to the washer.
(b) Install the washer onto the low planetary gear.
28. INSTALL TRANSFER INPUT GEAR STOPPER BALL
29. INSTALL TRANSFER INPUT GEAR STOPPER
30. 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.
31. 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
09316-00011
NOTICE:
Be careful not to damage the front case.
(b) Coat the lip of the oil 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 : 09304-12012
Standard depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)
NOTICE:
Be careful not to damage the front case.
(d) Coat the lip of the oil seal with MP grease.
32. INSTALL TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT
(a) Install the low planetary gear with input shaft.
HINT
If necessary, heat the front case 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.
33. INSTALL TRANSFER OIL PUMP GEAR
(a) Apply gear oil to the sliding surface of the gear.
(b) Install the gear with the nut.
34. INSTALL TRANSFER OIL PUMP BODY O-RING
(a) Coat a new O-ring with gear oil and install it onto the oil pump body.
35. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY
(a) Install the pump body with the 3 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
36. INSTALL TRANSFER CASE MAGNET
37. 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)
38. 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)
39. 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)
40. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING
(a) Apply gear oil to the contact surfaces of the bearing and the 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.
41. 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.
42. INSTALL REAR TRANSFER OUTPUT SHAFT, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY
(a) Install the output shaft and driven sprocket onto the front drive chain.
(b) Mount the rear case in a vise.
NOTICE:
Place aluminum plates on the vise to prevent damage to the rear case.
(c) Install the output shaft, front drive chain and driven sprocket onto the rear case.
HINT
Check that the output shaft and driven sprocket turn smoothly. If necessary, heat the rear case to about 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.
43. INSTALL CENTER DIFFERENTIAL LOCK FORK WITH FRONT DRIVE CLUTCH SLEEVE
(a) Install the clutch sleeve.
NOTICE:
Install the clutch sleeve in the correct direction.
(b) Install the front drive shift shaft, center differential lock fork, shift shaft stopper, 2 springs and 3 stoppers.
(c) Install the ball and spring into the hole.
(d) Apply sealant to the threads of the No. 2 plug.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(e) Install the No. 2 plug into the hole.
Torque : 19 Nm (190 kgf-cm, 14 ft-lbf)
(f) Using a pin punch and hammer, tap in the slotted pin.
NOTICE:
When installing the slotted pin, make sure the pin's groove (labeled A) is facing in the same direction as the shaft.
44. INSTALL NO. 2 TRANSFER GEAR SHIFT FORK WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE
(a) Install the synchronizer ring, 3 shifting keys and 2 springs.
NOTICE:
* Set the No. 1 springs so that their openings do not overlap, as shown in the illustration.
* Make sure that the No. 1 springs are firmly connected to the shifting keys.
(b) Install the straight pin into the hole.
(c) Install the No. 2 gear shift fork, high and low shift fork shaft and high and low clutch sleeve.
NOTICE:
Install the fork in the correct direction.
(d) Install the ball and spring into the hole.
(e) Apply sealant to the threads of the No. 1 plug.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(f) Install the No. 1 plug into the hole.
(g) Using a pin punch and hammer, install the slotted pin.
NOTICE:
When installing the slotted pin, make sure the pin's groove (labeled A) is facing in the same direction as the shaft.
45. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
(a) Apply gear oil to the bearing.
(b) Install the bearing onto the low planetary gear.
46. 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 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) apply FIPG to the rear case.
(b) Install the clamps 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.
47. INSTALL TRANSFER OUTPUT SHAFT WASHER
(a) Install the speedometer drive gear and 2 output washers.
48. INSTALL TRANSFER EXTENSION HOUSING TYPE T 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.
49. 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 extension housing's contact surface, 2) clean off any remaining old FIPG from the extension housing's contact surface, and 3) apply FIPG to the extension housing.
(b) Apply sealant to the threads of the bolt.
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.
50. INSTALL SPEEDOMETER DRIVEN GEAR SUB-ASSEMBLY
(a) Install a new O-ring onto the driven gear.
(b) Install the driven gear onto the sensor with the clip.
51. INSTALL SPEEDOMETER DRIVEN GEAR WITH VEHICLE SPEED SENSOR
(a) Install the sensor with driven gear with the bolt.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
(b) Connect the sensor connector.
52. 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.
(b) Coat the lip of the oil seal with MP grease.
53. 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.
(b) Coat the lip of the oil seal with MP grease.
54. 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
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.
55. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Rear)
(a) Apply gear oil to the connecting area of the companion flange and output shaft.
(b) Install the companion flange onto the output shaft.
(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)
56. INSTALL BREATHER OIL DEFLECTOR
57. 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)
58. INSTALL TRANSFER COVER TYPE T OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the retainer upper surface.
SST : 09950-60010
09951-00590
SST : 09950-70010
09951-07100
NOTICE:
Be careful not to damage the bearing retainer.
59. 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 bearing retainer's contact surface, 2) clean off any remaining old FIPG from the bearing retainer's contact surface, and 3) apply FIPG to the bearing retainer.
(b) Apply sealant to the threads of the bolt.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(c) Install the bearing 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.
60. INSTALL TRANSFER INDICATOR SWITCH
(a) Install new gaskets and the indicator switches.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
HINT
Indicator switch:
