Reassembly

JF3A TRANSFER / 4WD / AWD: TRANSFER ASSEMBLY: REASSEMBLY

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

1. INSTALL REAR TRANSFER OUTPUT SHAFT

(a) Install a new needle roller bearing.

(b) Install the transfer drive sprocket sub-assembly.

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

2. INSTALL FRONT DRIVE CLUTCH SLEEVE

(a) Install the transfer clutch hub onto the front drive clutch sleeve.

(b) Install the 3 shifting keys and 2 shifting key snap rings

NOTICE:
Install the key springs so that their end gaps are not in line.

(c) Install the synchronizer ring set.

NOTICE:
Align the slots of the synchronizer outer with the inner rings.

(d) Install the 2 transfer clutch hub bearings.

(e) Install the front drive clutch sleeve with synchromesh onto the output shaft.

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

3. INSTALL CENTER DIFFERENTIAL CASE

(a) Install the synchromesh shifting key spring and No. 2 synchromesh shifting keys as shown in the illustration.

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

(d) Install the straight pin to the output shaft.

4. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER

(a) Install a new seal ring to the output shaft spacer.

(b) Align the pin with the straight pin groove of the output shaft spacer, and slide on the output shaft spacer.

5. INSTALL TRANSFER INPUT SHAFT PLUG

(a) Using SST and a hammer, tap in a new input shaft plug until its surface is 1.0 to 1.8 mm (0.0394 to 0.0709 in.) from the input shaft upper surface.

SST : 09950-70010

09951-07150

SST : 09950-60010

09951-00380

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

6. INSTALL TRANSFER INPUT SHAFT BIMETAL FORMED BUSH

(a) Using SST and a hammer, tap in a new bush until its surface is 5.5 to 5.9 mm (0.217 to 0.232 in.) from the input shaft upper surface.

SST : 09950-70010

09951-07150

SST : 09950-60010

09951-00610

NOTICE:
Be careful not to damage the input shaft.

7. INSTALL TRANSFER INPUT SHAFT BEARING

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

NOTICE:
* Make sure that the low planetary gear bearing is installed in the correct direction.
* Install the low planetary gear bearing so that its temper color side faces the low planetary gear.

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

NOTICE:
* Make sure that the input shaft bearing is installed in the correct direction.
* Make sure that the low planetary gear bearing is installed in the correct direction.
* Install the low planetary gear bearing so that its temper color side faces the low planetary gear.

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

SST : 09513-36040

SST : 09527-17011

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

(d) Select a snap ring that allows for minimum axial play and install it to the shaft.

Snap Ring Thickness:

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

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

8. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING

(a) Apply transfer oil to a new seal ring.

(b) Install a new seal ring to the input shaft.

9. INSTALL TRANSFER DRIVEN SPROCKET BEARING

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

SST : 09950-60020

09951-00790

SST : 09950-70010

09951-07150

NOTICE:
Make sure that the bearing is installed in the correct direction.

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

10. INSTALL TRANSFER LOW PLANETARY RING GEAR

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

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

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

(c) Using a screwdriver install the snap ring.

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

11. INSTALL INPUT SHAFT ASSEMBLY

(a) While expanding the snap ring, install the input shaft to the front case.

(b) Apply adhesive to the threads of the 2 plugs.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTICE:
Install the plugs within 3 minutes of application.

(c) Using a 14 mm hexagon wrench, install the 2 plugs.

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

12. INSTALL TRANSFER CASE MAGNET

(a) Install the transfer case magnet.

13. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY

(a) Install a new O-ring.

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

Torque : 18 Nm (178 kgf-cm, 13 ft-lbf)

14. INSTALL SIDE GEAR SHAFT HOLDER BEARING

(a) Using SST and hammer, install a new side gear shaft holder bearing.

SST : 09950-60010

09951-00590

SST : 09950-70010

09951-07150

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

15. INSTALL REAR OUTPUT SHAFT

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

(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 rear output shaft , front drive chain and driven sprocket.

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

(d) Using a snap ring expander, install the snap ring to the out put shaft.

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

16. INSTALL TRANSFER HIGH & LOW CLUTCH SLEEVE

(a) Install the transfer high and low clutch sleeve to the output shaft.

17. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY

(a) Install the washer to the rear case.

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

(c) 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)

(d) Install the 2 bolts.

Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)

(e) Using a screwdriver and hammer, tap the 3 shift fork shaft snap rings into the shift fork shaft.

18. INSTALL NO. 1 SYNCHRONIZER RING

(a) Align the protrusion of the synchronizer ring with the notch on the differential case and install it.

19. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING

(a) Install the output shaft spacer.

(b) Install the transfer output shaft front needle roller bearing.

20. INSTALL REAR TRANSFER CASE

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

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
If the removed rear case will be reused: After removing the rear case, 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.

(b) Install the rear case with the 14 bolts.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

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

21. INSTALL TRANSFER CASE PLUG

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

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTICE:
Install the plug within 3 minutes of application.

(b) Using a 6 mm hexagon wrench, install the plug.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

22. 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

NOTICE:
Install the plug within 3 minutes of application.

(c) Install the plug.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

23. INSTALL TRANSFER CASE FRONT OIL SEAL

(a) Apply transfer oil to the spline area of the output shaft.

(b) Using SST and a hammer, tap in the oil seal until its surface is 1 to 1.5 mm (0.0394 to 0.0591 in.) from the case upper surface.

SST : 09316-60011

09316-00011

24. 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.

SST : 09330-00021

(c) Using a socket wrench (32mm), install a new O-ring and a new companion flange lock nut.

Torque : 127 Nm (1299 kgf-cm, 94 ft-lbf)

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

25. INSTALL TRANSFER CASE REAR OIL SEAL

(a) Install the 2 output washers.

(b) Apply transfer oil to the spline area of the output shaft.

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

SST : 09316-60011

09316-00011

26. 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.

SST : 09330-00021

27. INSTALL TRANSFER OIL PUMP PLATE OIL SEAL

SST : 09950-60020

09951-00680

SST : 09950-70010

09951-07100

(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 : 09950-70010

09951-07100

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

28. INSTALL TRANSFER CASE STRAIGHT PIN

(a) Install the 2 straight pins to the input shaft.

29. INSTALL TRANSFER OIL PUMP PLATE

(a) Apply transfer oil to a new O-ring, drive rotor and driven rotor.

(b) Install the O-ring.

(d) Install a new seal ring to the input shaft.

(e) Install the oil pump plate with the 4 bolts.

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

30. INSTALL TRANSFER CASE PLUG

(a) Install the relief valve seat, ball and compression spring 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)

31. INSTALL HEAT INSULATOR BRACKET

(a) Install the heat insulator bracket with the bolt.

NOTICE:
Position the bracket against the transfer case rib so that it will not rotate.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)