Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Tundra 2000-2006 Approved 04-06 techinfo.toyota.com ileaf 06toyrm 06toypdf 06rmsrc 06tundra tr traass disa

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disa

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TR-7
TRANSFER - TRANSFER ASSEMBLY
TR09K-03

DISASSEMBLY
1. REMOVE SPEEDOMETER DRIVEN GEAR HOLE COV-
ER
(a) Remove the bolt and speedometer driven gear hole cov-
er.
(b) Remove the O-ring from the speedometer driven gear
hole cover.
2. REMOVE PROTECTOR
Remove the 4 bolts and protector.

3. REMOVE FRONT BEARING RETAINER
(a) Remove the 5 bolts.
(b) Using a plastic hammer, tap on the front bearing retainer
and remove it.
4. REMOVE UPPER COVER AND OIL DEFLECTOR
Remove the 4 bolts, upper cover and oil deflector.

F07962

5. REMOVE FRONT COMPANION FLANGE
(a) Using a chisel and hammer, loosen the staked part of the
front companion flange lock nut.
SST (b) Using SST, hold the front companion flange and remove
the front companion flange lock nut.
SST 09330-00021

Q07159

(c) Using SST, remove the front companion flange.
SST 09950-40011 (09951-04020, 09952-04010,
09953-04030, 09954-04010, 09955-04051,
09957-04010, 09958-04011)
6. REMOVE REAR COMPANION FLANGE
Remove the rear companion flange in the same way as the front
companion flange.
SST

F07963

7. REMOVE EXTENSION HOUSING
(a) Remove the 5 bolts.
(b) Using a plastic hammer, tap on the extension housing and
remove it.
8. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
(a) Remove the 2 output washers and vehicle speed sensor
drive gear.
(b) Using a magnetic finger, remove the ball from the rear out-
F07964 put shaft.
TR-8
TRANSFER - TRANSFER ASSEMBLY

9. SEPARATE FRONT CASE AND REAR CASE
(a) Remove the 12 bolts and 2 clamps.
(b) Using a plastic hammer, tap on the front case and rear
case, and separate them.

F19348

10. REMOVE SHIFT FORK SHAFT
(a) Using a hexagon wrench (6 mm), remove the 2 straight
screw plugs, springs and balls from the front drive and
high and low shift forks.

F07965

(b) Using 2 screwdrivers and a hammer, tap out the 2 snap
rings from the shift fork shaft.

F07972

F07966
TR-9
TRANSFER - TRANSFER ASSEMBLY

High and Low Front Drive (d) To pull out the shift fork shaft, shift the front drive and high
Snap Ring Shift Fork Shift Fork and low shift forks to the positions as shown in the illustra-
tion.
(e) Pull out the shift fork shaft.

Shift Fork Shaft

Snap Ring

F07979

(f) Using a magnetic finger, remove the 2 straight pins from
the front drive and high and low shift forks.

F07980

11. REMOVE REAR OUTPUT SHAFT ASSEMBLY, DRIVEN
SPROCKET ASSEMBLY, CHAIN AND FRONT DRIVE
AND HIGH AND LOW SHIFT FORKS
(a) Using 2 screwdrivers and a hammer, tap out the snap ring
from the shift fork shaft of the actuator assembly.
HINT:
Remove only the snap ring on the front side of the shift fork
shaft.
F07967

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

F07968
TR-10
TRANSFER - TRANSFER ASSEMBLY

(c) Mount the rear case in a vise.
(d) Using a plastic hammer, carefully tap the rear case, and
remove the rear output shaft assembly, driven sprocket
assembly, chain and front drive and high and low shift
forks as an assembly.
(e) Remove the driven sprocket assembly, chain and front
drive and high and low shift forks from the rear output
shaft assembly.
F07969

12. REMOVE ACTUATOR ASSEMBLY
(a) Using 2 screwdrivers and a hammer, remove the snap
ring.
(b) Remove the 3 bolts and actuator assembly.

F07970

(c) Remove the O-ring, transfer 4WD position switch, trans-
fer L4 position switch and 2 gaskets from the actuator as-
sembly.

F07971

13. REMOVE SEPARATOR WITH OIL STRAINER AND
MAGNET
Remove the 3 bolts and separator with the oil strainer and mag-
net.

D03238

14. REMOVE OIL PUMP BODY ASSEMBLY
Remove the 3 bolts and oil pump body assembly.
15. REMOVE OIL PUMP DRIVE GEAR

Q07218
TR-11
TRANSFER - TRANSFER ASSEMBLY

16. REMOVE PLANETARY GEAR ASSEMBLY WITH
INPUT SHAFT ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.

Q07220

(b) Pull out the planetary gear assembly with the input shaft
assembly.

Q07221

17. REMOVE LOW GEAR SPLINE PIECE
(a) Using a screwdriver, remove the snap ring.

TF0472

(b) Remove the low gear spline piece.

TF0473

18. REMOVE NEEDLE ROLLER BEARING FROM INPUT
SHAFT ASSEMBLY

TF0474
TR-12
TRANSFER - TRANSFER ASSEMBLY

19. REMOVE INPUT GEAR STOPPER AND THRUST
WASHER
(a) Using a snap ring expander, remove the snap ring.

Q07289

(b) Remove the input gear stopper, ball and thrust washer.

F19349

20. REMOVE INPUT SHAFT ASSEMBLY, THRUST BEAR-
ING AND RACE

Q07437

21. REMOVE PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring.

Q07240

(b) Remove the head screw plug, spring and pin.

Q07241
TR-13
TRANSFER - TRANSFER ASSEMBLY

Q07290

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