WORKSHEET 5-1

Transfer CaseDisassembly and Component Identification

Vehicle:

Year/Prod. Date:

Engine

Transmission:

Worksheet Objectives
With this worksheet, you will follow the disassembly of a four wheel drive transfer case using the
required special tools, make measurements where appropriate, retrieve and apply the needed service
information, retrieve and interpret service specification information from the repair manual.
Tools and Equipment
Vehicle Repair Manual
Hand Tool Set
Dial Indicator and Stand
Micrometer, 0-1 in.
Feeler Gauge
Section 1: Case Disassembly

1. Remove the front bearing retainer and front and rear companion flanges.
a. What Special Service Tool is used to remove the companion flange?

b. Is this Special Service Tool an essential tool or available tool?

2. Remove extension housing and speedometer drive gear. (Caution: Dont loose the steel ball)
3. Remove the detent plugs, springs and balls.
4. Separate the case halves and remove the front case.
5. What shaft turns to drive the oil pump?

Manual Transmissions & Transaxles Course 302

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Worksheet 5-1

6. Is the vehicle dinghy tow able?

Section 2: Component Identification

Match the component names listed below with the parts in the illustration. Place the letter that
identifies the part on the line in front of the component name.

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1. Transfer input shaft

6. Drive sprocket

2. Planetary gear set

7. Driven sprocket

3. Rear output shaft

8. Front drive clutch sleeve

4. Silent chain

9. High low clutch sleeve

5. Front output shaft

10. Oil pump

TOYOTA Technical Training

Transfer CaseDisassembly and Component Identification

Section 3: Gears, Shafts and Shift Linkage Removal

1. STOP proceed only as directed by your instructor.
2. Remove the shift forks and shift fork shafts. Shift forks are secured to the shaft with a roll pin or in
some cases with a double roll pin. The position of the roll pin slit is essential to preventing the pin
from being compressed and working its way from the shift shaft. Explain how the roll pin should
be placed into position.

3. Remove the output shaft, chain and front drive sprocket.

4. Remove the oil pump and planetary gear assembly with input shaft.
Section 4: Clearance Measurement
1. Measure the rear output shaft drive sprocket thrust clearance:
Measurement:

Specification:

(If the clearance exceeds the maximum, the sprocket should be replaced.)
2. Measure the input shaft and planetary gear thrust bearing axial play:
Measurement:

Specification:

Manual Transmissions & Transaxles Course 302

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Worksheet 5-1

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TOYOTA Technical Training

Transfer CaseDisassembly and Component Identification

Transfer CaseDisassembly & Component Identification

Name:

Date:

Review this sheet as you are doing the Transfer CaseDisassembly & Component Identification
worksheet. Check each category after viewing the instructors presentation and completing the
worksheet. Ask the instructor if you have questions regarding the topics provided below. Additional
space is provided under Topic for you to list any other concerns that you would like your instructor to
address. The comments section is provided for your personal comments, information, questions, etc.
I have questions

I know I can

Topic

Comment

Identify all gears in the transfer case.

Identify all synchronizers in the transfer

case.
Explain how 2WD and 4WD is engaged.

Explain how 4 low and 4 high is engaged.

Measure output shaft drive sprocket

thrust clearances.
Measure input shaft and planetary gear
thrust bearing axial play.

Manual Transmissions & Transaxles Course 302

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Worksheet 5-1

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TOYOTA Technical Training

Transfer CaseDisassembly and Component Identification

WORKSHEET 5-2
Transfer CaseReassembly

Vehicle:

Year/Prod. Date:

Engine

Transmission:

Worksheet Objectives
With this worksheet, you will follow the assembly of a four wheel drive transfer case using the
required special tools, make measurements where appropriate, retrieve and apply the needed service
information, retrieve and interpret service specification information from the repair manual.
Tools and Equipment
Vehicle Repair Manual
Hand Tool Set
Dial Indicator and Stand
Micrometer, 0-1 in.
Feeler Gauge
Section 1: Case Reassembly

1. Assemble planetary gear assembly.

2. Using a dial indicator, measure the input shaft axial play:
Measurement:

Specification:

3. If the snap ring has a mark designation of H and the axial play is 0.009 in., what is the mark
designation of the shim that will bring the axial play within specification?

4. What component holds the planetary ring gear from rotating?

5. Assemble rear output shaft

Manual Transmissions & Transaxles Course 302

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Worksheet 5-1

6. Remeasure the rear output shaft drive sprocket thrust clearance following assembly:
Measurement:

Specification:

7. Install the planetary gear assembly, oil pump, rear output shaft, chain and driven sprocket.
8. Install the shift forks, shift shafts, rear case and extension housing.

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TOYOTA Technical Training

Transfer CaseDisassembly and Component Identification

Transfer CaseReassembly
Name:

Date:

Review this sheet as you are doing the Transfer CaseReassembly worksheet. Check each
category after viewing the instructors presentation and completing the worksheet. Ask the instructor if
you have questions regarding the topics provided below. Additional space is provided under topic for
you to list any other concerns that you would like your instructor to address. The comments section is
provided for your personal comments, information, questions, etc.

I have questions

I know I can

Topic

Comment

Determine shim mark designation from

the repair manual shim chart.
Use a dial indicator to measure input
shaft axial play.
Explain the application of FIPG to the
transfer case sealing surfaces.

Manual Transmissions & Transaxles Course 302

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Worksheet 5-1

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TOYOTA Technical Training