Transfer Case (Service Information): Overview Lexus GX J150

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1. CHECK TRANSFER OIL Remove the filler plug and gasket. Check that the oil level is between 0 to 5.0 mm (0 to 0.196 in.) from the bottom lip of the filler plug hole. If the result is not as specified, add transfer oil. TEXT IN ILLUSTRATION *a 0 to 5 mm NOTE: Too much or too little oil will lead to transfer problems. When the oil level is too low, check for oil leaks. Install a new gasket to the filler plug and then tighten the plug. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
2. ADD TRANSFER OIL Remove the filler plug and gasket. Add oil so that the oil level is between 0 to 5.0 mm (0 to 0.196 in.) from the bottom lip of the filler plug hole. NOTE: Add oil slowly. Add oil a little at a time, waiting several minutes between each addition of oil. HINT: Oil type Toyota Genuine Transfer Gear oil LF or equivalent Viscosity SAE 75W Capacity 1.4 liters (1.5 US qts, 1.2 lmp.qts) Wait approximately 5 minutes and check that the oil level has not changed. Install a new gasket to the filler plug and then tighten the plug. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)

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1. DRAIN TRANSFER OIL Remove the filler plug and gasket. Remove the drain plug and gasket, and drain the transfer oil. Install a new gasket and the drain plug. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
2. ADD TRANSFER OIL See step 2

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1. DRAIN TRANSFER OIL See step 1
2. REMOVE FRONT PROPELLER SHAFT ASSEMBLY Remove the front propeller shaft. Refer to «REMOVAL»(ref-524259-S30365338342013012800000) .
3. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See step 6
4. REMOVE FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL See step 7
5. REMOVE TRANSFER CASE FRONT OIL SEAL Using SST, tap out the oil seal. SST: 09308-00010 NOTE: Be careful not to damage the oil seal and front case contact surface.
6. INSTALL TRANSFER CASE FRONT OIL SEAL Coat the lip of a new oil seal with MP grease. Using SST and a hammer, tap in the oil seal until its metal ring contacts the case. SST: 09649-17010 SST: 09950-70010 09951-07100
7. INSTALL FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL See step 54
8. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See step 55
9. INSTALL FRONT PROPELLER SHAFT ASSEMBLY Install the front propeller shaft. Refer to «INSTALLATION»(ref-524259-S23344061322013012800000) .
10. ADD TRANSFER OIL See step 2
11. CHECK FOR TRANSFER OIL LEAK

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1. DRAIN TRANSFER OIL See step 1
2. REMOVE REAR PROPELLER SHAFT ASSEMBLY Remove the rear propeller shaft. Refer to «REMOVAL»(ref-524259-S34527760322013012800000) .
3. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See step 9
4. REMOVE REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL See step 10
5. REMOVE TRANSFER CASE REAR OIL SEAL Using SST, tap out the oil seal. SST: 09308-00010 NOTE: Be careful not to damage the oil seal and rear case contact surface.
6. INSTALL TRANSFER CASE REAR OIL SEAL Coat the lip of a new oil seal with MP grease. Using SST and a hammer, tap in the oil seal until its surface is flush with the case upper surface. SST: 09223-46011 SST: 09631-32020
7. INSTALL REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL See step 51
8. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See step 52
9. INSTALL PROPELLER SHAFT ASSEMBLY Install the rear propeller shaft. Refer to «INSTALLATION»(ref-524259-S24827381652013012800000) .
10. ADD TRANSFER OIL See step 2
11. CHECK FOR TRANSFER OIL LEAK

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1. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER Remove the automatic transmission with transfer. Refer to «REMOVAL»(ref-524256-S08579335952013012800000) .
2. REMOVE TRANSFER ASSEMBLY Remove the 8 bolts. Remove the transfer from the transmission.

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1. REMOVE HOSE Detach the clamp and remove the hose.
2. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY Remove the 5 bolts and bearing retainer. HINT: If necessary, tap the bearing retainer with a plastic-faced hammer to remove it.
3. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL Using a screwdriver and hammer, remove the oil seal from the bearing retainer.
4. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY Remove the 4 bolts and case cover.
5. REMOVE BREATHER OIL DEFLECTOR Remove the oil deflector.
6. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY Using a chisel and hammer, loosen the staked part of the lock nut. Using SST to hold the companion flange, remove the lock nut. SST: 09330-00021 Using SST, remove the companion flange. SST: 09950-40011 09951-04020 09952-04010 09953-04030 09954-04010 09955-04051 09957-04010 09958-04011
7. REMOVE FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL Using a screwdriver and hammer, tap out the oil seal from the companion flange. NOTE: Be careful not to damage the oil seal and companion flange contact surfaces.
8. REMOVE TRANSFER CASE FRONT OIL SEAL See step 5
9. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY Using a chisel and hammer, loosen the staked part of the lock nut. Using SST to hold the companion flange, remove the lock nut. SST: 09330-00021 Using SST, remove the companion flange. SST: 09950-40011 09951-04020 09952-04010 09953-04030 09954-04010 09955-04051 09957-04010 09958-04011
10. REMOVE REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL Using a screwdriver and hammer, tap out the oil seal from the companion flange. NOTE: Be careful not to damage the oil seal and companion flange contact surfaces.
11. REMOVE TRANSFER CASE REAR OIL SEAL See step 5
12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY Remove the 5 bolts and extension housing. HINT: If necessary, tap the extension housing with a plastic-faced hammer to remove it.
13. REMOVE TRANSFER OUTPUT SHAFT WASHER Remove the 2 washers.
14. REMOVE COLLAR Remove the collar.
15. REMOVE REAR TRANSFER CASE Remove the 12 bolts and clamp. Remove the rear transfer case. HINT: If necessary, tap the rear transfer case with a plastic-faced hammer to remove it.
16. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK SUB-ASSEMBLY WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE Remove the bolt, No. 2 gear shift fork, and high and low clutch sleeve.
17. REMOVE CENTER DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE Using 2 screwdrivers and a hammer, tap off the snap ring. Remove the bolt, center differential lock fork and front drive clutch sleeve.
18. REMOVE REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY Mount the rear transfer case in a vise. Using a snap ring expander, remove the snap ring. Using a plastic-faced hammer, carefully tap the rear transfer case, and remove the rear output shaft together with the front drive chain and driven sprocket. Remove the rear output shaft, front drive chain and driven sprocket.
19. REMOVE TRANSFER DRIVEN SPROCKET BEARING Using SST and a press, remove the driven sprocket bearing. SST: 09555-55010 NOTE: Be careful not to drop or damage the driven sprocket.
20. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING Using SST and a press, remove the transfer input gear radial ball bearing. SST: 09555-55010 NOTE: Be careful not to drop or damage the driven sprocket.
21. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY Using 2 screwdrivers and a hammer, tap off the 2 snap rings. Remove the 3 bolts and transfer shift actuator.
22. REMOVE FILLER PLUG Remove the filler plug and gasket.
23. REMOVE DRAIN PLUG Remove the drain plug and gasket.
24. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY Remove the 3 bolts and oil separator.
25. REMOVE TRANSFER CASE MAGNET
26. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY Remove the 3 bolts and oil pump body.
27. REMOVE TRANSFER OIL PUMP BODY O-RING Using a screwdriver, remove the oil pump body O-ring. NOTE: Be careful not to damage the oil pump body.
28. REMOVE TRANSFER OIL PUMP GEAR Remove the transfer oil pump gear.
29. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT SUB-ASSEMBLY Using a snap ring expander, remove the snap ring. Remove the low planetary gear together with the input shaft.
30. REMOVE TRANSFER OUTPUT SHAFT SPACER Remove the transfer output shaft spacer.
31. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING Remove the needle roller bearing.
32. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING Using a snap ring expander, remove the snap ring.
33. REMOVE TRANSFER INPUT GEAR STOPPER Remove the input gear stopper.
34. REMOVE TRANSFER INPUT GEAR STOPPER BALL Remove the ball.
35. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER Remove the washer.
36. REMOVE TRANSFER INPUT SHAFT Remove the transfer input shaft.
37. REMOVE NO. 1 TRANSFER THRUST BEARING RACE Remove the thrust bearing race.
38. REMOVE TRANSFER LOW PLANETARY GEAR THRUST BEARING Remove the bearing.
39. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING Remove the 2 seal rings.
40. REMOVE TRANSFER INPUT SHAFT BEARING Using a snap ring expander, remove the snap ring. Using SST and a press, remove the input shaft bearing. SST: 09555-55010 SST: 09950-70010 09951-07150 SST: 09950-60020 09951-00750 NOTE: Be careful not to drop or damage the low planetary gear.
41. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE Using a screwdriver, remove the snap ring. Remove the low planetary gear spline piece.
42. REMOVE TRANSFER LOW PLANETARY GEAR BEARING Using SST, remove the low planetary gear bearing. SST: 09612-65014 09612-01030 09612-01050 NOTE: Make sure SST fits securely in the space between the bearing and low planetary gear.
43. REMOVE NO. 2 TRANSFER OUTPUT SHAFT SPACER Using a snap ring expander, remove the snap ring. Remove the spacer.
44. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL Remove the ball.
45. REMOVE CENTER DIFFERENTIAL CASE Remove the center differential case.
46. REMOVE TRANSFER CLUTCH HUB Remove the transfer clutch hub.
47. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING Remove the needle roller bearing.
48. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER Remove the washer.
49. REMOVE REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING Using SST and a press, remove the bearing. SST: 09555-55010
50. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER Remove the output shaft spacer.
51. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY Remove the transfer drive sprocket.
52. REMOVE TRANSFER DRIVE SPROCKET BEARING Remove the bearing.
53. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER Remove the washer.
54. REMOVE TRANSFER CASE PLUG Remove the transfer case plug.
55. REMOVE COMPRESSION SPRING Remove the spring.
56. REMOVE PIN Remove the pin.
57. REMOVE TRANSFER LOW PLANETARY RING GEAR Using a screwdriver, remove the snap ring. Remove the low planetary ring gear from the front transfer case.

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1. INSPECT TRANSFER INPUT SHAFT Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum diameter 47.59 mm (1.88 in.) If the outer diameter is less than the minimum, replace the input shaft.
2. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the thrust clearance of the planetary pinion gear. Standard clearance 0.11 to 0.84 mm (0.00434 to 0.0330 in.) Maximum clearance 0.84 mm (0.0330 in.) If the clearance is more than the maximum, replace the planetary gear.
3. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE Using a dial indicator, measure the radial clearance of the planetary pinion gear. Standard clearance 0.009 to 0.038 mm (0.000355 to 0.00149 in.) Maximum clearance 0.038 mm (0.00149 in.) If the clearance is more than the maximum, replace the planetary gear.
4. INSPECT TRANSFER OUTPUT SHAFT REAR Using a micrometer, measure the outer diameter of the output shaft rear journal surfaces. Standard diameter Journal A 27.98 to 27.99 mm (1.1016 to 1.1019 in.) Journal B 31.98 to 32.00 mm (1.2591 to 1.2598 in.) Journal C 34.98 to 35.00 mm (1.3772 to 1.3779 in.) Journal D 36.98 to 37.00 mm (1.4560 to 1.4566 in.) Minimum diameter Journal A 27.98 mm (1.1016 in.) Journal B 31.98 mm (1.2591 in.) Journal C 34.98 mm (1.3772 in.) Journal D 36.98 mm (1.4560 in.) If the outer diameter is less than the minimum, replace the rear output shaft.
5. INSPECT TRANSFER HIGH AND LOW CLUTCH SLEEVE AND NO. 2 TRANSFER GEAR SHIFT FORK CLEARANCE Using a vernier caliper, measure the thickness of the shift fork claw. Standard thickness (A) 10 mm (0.394 in.) Using a vernier caliper, measure the width of the groove of the high and low clutch sleeve. Standard width (B) 10.5 mm (0.413 in.) Calculate the clearance between the high and low clutch sleeve and shift fork. Standard clearance (B) - (A) 0.26 to 0.84 mm (0.0103 to 0.0330 in.) Maximum clearance (B) - (A) 0.84 mm (0.0330 in.) If the clearance is more than the maximum, replace the high and low clutch sleeve or shift fork.
6. INSPECT FRONT DRIVE CLUTCH SLEEVE AND CENTER DIFFERENTIAL LOCK FORK SUB-ASSEMBLY CLEARANCE Using a vernier caliper, measure the thickness of the center differential lock fork claw. Standard thickness (A) 10 mm (0.394 in.) Using a vernier caliper, measure the width of the groove of the front drive clutch sleeve. Standard width (B) 10.5 mm (0.413 in.) Calculate the clearance between the front drive clutch sleeve and differential lock fork. Standard clearance (B) - (A) 0.26 to 0.84 mm (0.0103 to 0.0330 in.) Maximum clearance (B) - (A) 0.84 mm (0.0330 in.) If the clearance is more than the maximum, replace the front drive clutch sleeve or differential lock fork.
7. INSPECT CENTER DIFFERENTIAL CASE AND TRANSFER HIGH AND LOW CLUTCH SLEEVE Check that the splines of the clutch sleeve are not worn. Install the clutch sleeve to the center differential case and check that the clutch sleeve moves smoothly.
8. INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE Check that the splines of the clutch sleeve are not worn. Install the clutch sleeve to the center differential case and check that the clutch sleeve moves smoothly.

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1. INSTALL TRANSFER LOW PLANETARY RING GEAR Install the low planetary ring gear to the front transfer case. Using a screwdriver, install the snap ring.
2. INSTALL PIN Install the pin.
3. INSTALL COMPRESSION SPRING Install the spring.
4. INSTALL TRANSFER CASE PLUG Install the transfer case plug. Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf)
5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER Install the washer.
6. INSTALL TRANSFER DRIVE SPROCKET BEARING Install the bearing.
7. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY Install the transfer drive sprocket.
8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER Install the output shaft spacer.
9. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING Using SST and a press, install a new bearing. SST: 09316-60011 09316-00011 09316-00071 TEXT IN ILLUSTRATION *1 Groove Rear NOTE: Install the bearing so that the bearing snap ring groove faces the rear.
10. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER Install the washer.
11. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING Install the needle roller bearing.
12. INSTALL TRANSFER CLUTCH HUB Install the transfer clutch hub.
13. INSTALL CENTER DIFFERENTIAL CASE Install the center differential case.
14. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL Install the ball.
15. INSTALL NO. 2 TRANSFER OUTPUT SHAFT SPACER Install the spacer. Using a snap ring expander, install the snap ring.
16. INSPECT DRIVE SPROCKET RADIAL CLEARANCE Using a dial indicator, measure the radial clearance of the drive sprocket. Standard clearance 0.01 to 0.06 mm (0.000394 to 0.00236 in.) Maximum clearance 0.06 mm (0.00236 in.) If the clearance is more than the maximum, replace the drive sprocket, rear output shaft or bearing.
17. INSPECT DRIVE SPROCKET THRUST CLEARANCE Using a feeler gauge, measure the thrust clearance of the drive sprocket. Standard clearance 0.15 to 0.24 mm (0.00591 to 0.00944 in.) Maximum clearance 0.24 mm (0.00944 in.) If the clearance is more than the maximum, replace the drive sprocket.
18. INSTALL TRANSFER INPUT SHAFT BEARING Using SST and a press, install a new bearing with the groove facing forward. SST: 09223-15020 SST: 09515-30010 SST: 09950-70010 09951-07100
19. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING Select a new snap ring that allows minimal axial play. Standard Snap Ring Thickness Mark Specified Condition 1 1.45 to 1.50 mm (0.0571 to 0.0591 in.) 2 1.50 to 1.55 mm (0.0591 to 0.0610 in.) 3 1.55 to 1.60 mm (0.0610 to 0.0630 in.) 4 1.60 to 1.65 mm (0.0630 to 0.0650 in.) 5 1.65 to 1.70 mm (0.0650 to 0.0669 in.) Using a snap ring expander, install the snap ring.
20. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE Using a screwdriver, install the low planetary gear spline piece and snap ring.
21. INSTALL TRANSFER LOW PLANETARY GEAR BEARING Using SST and a press, press in a new low planetary gear bearing. SST: 09950-60010 09951-00570 SST: 09950-70010 09951-07100 Press in depth 7.7 to 8.3 mm (0.304 to 0.326 in.)
22. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING Apply gear oil to 2 new seal rings. Install the 2 seal rings to the input shaft. NOTE: When installing the seal ring, make sure not to expand it so that its inner diameter exceeds 65 mm (2.56 in.).
23. INSTALL TRANSFER LOW PLANETARY GEAR THRUST BEARING Install the bearing. TEXT IN ILLUSTRATION Front
24. INSTALL NO. 1 TRANSFER THRUST BEARING RACE Install the thrust bearing race.
25. INSTALL TRANSFER INPUT SHAFT Install the transfer input shaft.
26. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER Install the washer.
27. INSTALL TRANSFER INPUT GEAR STOPPER BALL Install the ball.
28. INSTALL TRANSFER INPUT GEAR STOPPER Install the input gear stopper.
29. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING Select a new input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.00197 to 0.00590 in.) of axial play. Standard Snap Ring Thickness Mark Specified Condition A 2.10 to 2.15 mm (0.0827 to 0.0846 in.) B 2.15 to 2.20 mm (0.0846 to 0.0866 in.) C 2.20 to 2.25 mm (0.0866 to 0.0886 in.) D 2.25 to 2.30 mm (0.0886 to 0.0906 in.) E 2.30 to 2.35 mm (0.0906 to 0.0925 in.) F 2.35 to 2.40 mm (0.0925 to 0.0945 in.) G 2.40 to 2.45 mm (0.0945 to 0.0965 in.) H 2.45 to 2.50 mm (0.0965 to 0.0984 in.) J 2.50 to 2.55 mm (0.0984 to 0.100 in.) K 2.55 to 2.60 mm (0.100 to 0.102 in.) L 2.60 to 2.65 mm (0.102 to 0.104 in.) M 2.65 to 2.70 mm (0.104 to 0.106 in.) N 2.70 to 2.75 mm (0.106 to 0.108 in.) P 2.75 to 2.80 mm (0.108 to 0.110 in.) Q 2.80 to 2.85 mm (0.110 to 0.112 in.) R 2.85 to 2.90 mm (0.112 to 0.114 in.) S 2.90 to 2.95 mm (0.114 to 0.116 in.) T 2.95 to 3.00 mm (0.116 to 0.118 in.) U 3.00 to 3.05 mm (0.118 to 0.120 in.) Using a snap ring expander, install the snap ring.
30. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT SUB-ASSEMBLY Install the low planetary gear together with the input shaft. Using a snap ring expander, install the shaft snap ring.
31. INSTALL TRANSFER OIL PUMP GEAR Install the transfer oil pump gear.
32. INSTALL TRANSFER OIL PUMP BODY O-RING Coat a new O-ring with gear oil and install it to the oil pump body.
33. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY Install the oil pump body with the 3 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
34. INSTALL TRANSFER CASE MAGNET
35. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY Install the oil separator with the 3 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
36. INSTALL FILLER PLUG Install a new gasket and the filler plug. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
37. INSTALL DRAIN PLUG Install a new gasket and the drain plug. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
38. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY Install the shift actuator with the 3 bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Using a screwdriver and hammer, tap on the 2 snap rings.
39. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING Using SST and a press, install a new input gear radial ball bearing. SST: 09316-60011 09316-00031
40. INSTALL TRANSFER DRIVEN SPROCKET BEARING Using SST and a press, install a new driven sprocket bearing. SST: 09316-60011 09316-00071
41. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY Install the rear output shaft and driven sprocket to the front drive chain. Install the rear output shaft, front drive chain and driven sprocket to the rear transfer case. HINT: Check that the rear output shaft and driven sprocket turn without much effort. Using a snap ring expander, install the snap ring. NOTE: Make sure that the snap ring is firmly installed to the groove.
42. INSTALL CENTER DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE Install the center differential lock fork and front drive clutch sleeve. TEXT IN ILLUSTRATION Front NOTE: Install the clutch sleeve in the correct direction. Install the bolt. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) Using a screwdriver and hammer, drive in the snap ring.
43. INSTALL NO. 2 TRANSFER GEAR SHIFT FORK SUB-ASSEMBLY WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE Install the No. 2 gear shift fork and high and low clutch sleeve. TEXT IN ILLUSTRATION Front NOTE: Install the clutch sleeve in the correct direction. Install the bolt. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
44. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING Install the needle roller bearing to the input shaft.
45. INSTALL TRANSFER OUTPUT SHAFT SPACER Install the transfer output shaft spacer to the input shaft.
46. INSTALL REAR TRANSFER CASE Apply seal packing to the rear transfer case as shown in the illustration. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent TEXT IN ILLUSTRATION *1 Seal Packing NOTE: If the removed rear transfer case is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the rear transfer case contact surface, 2) clean off any remaining old seal packing from the rear transfer case contact surface, and 3) reapply seal packing to the rear transfer case. Install the clamp and rear transfer case with the 12 bolts. Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) NOTE: Tighten the bolts of the rear transfer case within 10 minutes of applying the seal packing. The seal packing will dry very quickly.
47. INSTALL COLLAR Install the collar.
48. INSTALL TRANSFER OUTPUT SHAFT WASHER Install the 2 washers.
49. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY Apply seal packing to the extension housing as shown in the illustration. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent TEXT IN ILLUSTRATION *1 Seal Packing NOTE: If the removed extension housing is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the housing contact surface, 2) clean off any remaining old seal packing from the housing contact surface, and 3) reapply seal packing to the housing. Apply adhesive to the threads of the bolts. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Install the extension housing with the 5 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) NOTE: Tighten the bolts of the extension housing within 10 minutes of applying the seal packing. The seal packing will dry very quickly.
50. INSTALL TRANSFER CASE REAR OIL SEAL See step 6
51. INSTALL REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL Using SST and a hammer, tap in a new oil seal. SST: 09950-60010 09951-00320 SST: 09950-70010 09951-07100 Coat the lip of the oil seal with MP grease.
52. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY Apply gear oil to the connecting areas of the companion flange and output shaft. Install the companion flange to the output shaft. TEXT IN ILLUSTRATION Rear Using SST to hold the companion flange, install a new lock nut. SST: 09330-00021 Torque: 118 N*m (1203 kgf*cm, 87 ft.*lbf) Using a chisel and hammer, stake the lock nut. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT NOTE: Securely stake the shaft to the lock nut groove. Be careful not to damage the parts around the lock nut. Do not apply excessive force to the shaft.
53. INSTALL TRANSFER CASE FRONT OIL SEAL See step 6
54. INSTALL FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL Using SST and a hammer, tap in a new oil seal. SST: 09950-60010 09951-00320 SST: 09950-70010 09951-07100 Coat the lip of the oil seal with MP grease.
55. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY Apply gear oil to the connecting areas of the companion flange and driven sprocket. Install the companion flange to the driven sprocket. TEXT IN ILLUSTRATION Front Using SST to hold the companion flange, install a new lock nut. SST: 09330-00021 Torque: 118 N*m (1203 kgf*cm, 87 ft.*lbf) Using a chisel and hammer, stake the lock nut. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT NOTE: Securely stake the shaft to the lock nut groove. Be careful not to damage the parts around the lock nut. Do not apply excessive force to the shaft.
56. INSTALL BREATHER OIL DEFLECTOR Install the oil deflector.
57. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY Install the case cover with the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
58. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL 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 Coat the lip of the oil seal with MP grease.
59. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY Apply seal packing to the bearing retainer as shown in the illustration. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent TEXT IN ILLUSTRATION *1 Seal Packing NOTE: If the removed bearing retainer is reused, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old seal packing on the retainer contact surface, 2) clean off any remaining old seal packing from the retainer contact surface, and 3) reapply seal packing to the retainer. Apply sealant to the bolt threads. Sealant Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Install the retainer with the 5 bolts. Torque: 12 N*m (117 kgf*cm, 8 ft.*lbf) NOTE: Tighten the bolts of the bearing retainer within 10 minutes of applying the seal packing. The seal packing will dry very quickly.
60. INSTALL HOSE Attach the clamp and install the hose.

See also:
• REMOVAL - Step 6