Page 3097 of 3115

TR069-02
D02653
Gasket
Rear Extension
Housing
Vehicle Speed Sensor
Driven Gear
Oil Strainer
Case Cover Transfer Indicator Switch
(Neutral Switch)
Transfer Indicator Switch
(Low Switch)
37 (380, 27)
37 (380, 27)
37 (380, 27)
x9
37 (380, 27)
37 (380, 27)
x5 Adjusting Shim
Rear Case
Snap Ring Center Differential
Assemblyx8
Bearing Race
Shift Fork No. 1
Idler Gear Assembly Bearing Race
Shift Fork No. 1 Shaft
Bearing Race
Bearing Race
Input Shaft Assembly
Lever Lock Pin
Washer
Oil Seal
Shift Inner Lever
Oil Receiver Motor ActuatorShift Outer Lever
11 (115, 8)
4.9 (50, 43 in.´lbf)
19 (190, 14)18 (185, 13)
12 (120, 9)
12 (120, 9)
37 (380, 27)
37 (380, 27)
x6 Transfer Indicator Switch
(Center Diff. Lock) Shift Fork No. 2 Shift Fork No. 2 ShaftOutput Gear
Snap Ring
Front Case
Breather Hose
Clutch Sleeve
Front Extension Housing Oil Seal
N´m (kgf´cm, ft´lbf)
: Specified torque
Non-reusable part
Precoated partSpring
Ball Screw Plug
Gasket
Slotted Spring Pin
Washer
- TRANSFERTRANSFER ASSEMBLY
TR-7
1895 Author: Date:
2004 LAND CRUISER (RM1071U)
TRANSFER ASSEMBLY
COMPONENTS
Page 3098 of 3115
TR06X-02
D02690
D02862
Q07105
D02860
TR-8
- TRANSFERTRANSFER ASSEMBLY
1896 Author: Date:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. REMOVE BREATHER HOSE
2. REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR
Remove the bolt and driven gear.
3. REMOVE MOTOR ACTUATOR
Remove the 4 bolts and motor actuator.
4. REMOVE OUTPUT GEAR FROM FRONT CASE
5. REMOVE SCREW PLUG, SPRING AND BALL
(a) Using a torx socket wrench (T40), remove the screw plug.
(b) Using a magnetic finger, remove the spring and ball.
6. REMOVE TRANSFER INDICATOR SWITCH
Remove the 3 transfer indicator switches and 3 gaskets.
7. REMOVE FRONT EXTENSION HOUSING
Remove the 6 bolts and front extension housing.
HINT:
If necessary, tap the front extension housing lightly with a plas-
tic hammer.
Page 3099 of 3115
Q00541
Front
Q02950
D02861
D02667
D02863
- TRANSFERTRANSFER ASSEMBLY
TR-9
1897 Author: Date:
2004 LAND CRUISER (RM1071U)
8. REMOVE CLUTCH SLEEVE WITH SHIFT FORK NO. 2
SHAFT AND SHIFT FORK NO. 2
9. SEPARATE SHIFT FORK NO. 2 SHAFT AND SHIFT
FORK NO. 2
(a) Using 2 screwdrivers and a hammer, tap out the 3 snap
rings from the shift fork No. 2 shaft.
(b) Separate the shift fork No. 2 shaft and shift fork No. 2.
10. REMOVE REAR EXTENSION HOUSING
Remove the 9 bolts and rear extension housing.
HINT:
If necessary, tap the rear extension housing lightly with a plastic
hammer.
11. REMOVE ADJUSTING SHIMS
12. REMOVE OIL STRAINER FROM REAR CASE
Remove the 2 bolts and oil strainer.
13. REMOVE CASE COVER
(a) Remove the 5 bolts.
Page 3100 of 3115
D02668
D02669
D02864
TF0854
D02670
TR-10
- TRANSFERTRANSFER ASSEMBLY
1898 Author: Date:
2004 LAND CRUISER (RM1071U)
(b) Using a brass bar and hammer, tap the case cover and
remove it.
14. SEPARATE FRONT CASE AND REAR CASE
(a) Using a snap ring expander, remove the snap ring from
the rear case.
(b) Remove the 8 bolts.
(c) Using a brass bar and hammer, tap the rear case and sep-
arate it.
15. REMOVE 2 BEARING RACES FROM REAR CASE
16. REMOVE INPUT SHAFT ASSEMBLY
Using a plastic hammer, remove the input shaft assembly from
the front case.
Page 3101 of 3115

TF0986
TF0857
D04308
Socket Wrench
D02671
TF0862
SST
- TRANSFERTRANSFER ASSEMBLY
TR-1 1
1899 Author: Date:
2004 LAND CRUISER (RM1071U)
17. REMOVE IDLER GEAR ASSEMBLY WITH CENTER
DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND
SHIFT FORK NO. 1 SHAFT FROM FRONT CASE
18. SEPARATE SHIFT FORK NO. 1 AND SHIFT FORK NO.
1 SHAFT
(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Separate the shift fork No. 1 and shift fork No. 1 shaft.
19. REMOVE SHIFT OUTER LEVER AND INNER LEVER
(a) Remove the nut and washer from the shift outer lever.
(b) Using a brass bar, hammer and socket wrench, tap out
the lever lock pin.
(c) Remove the shift outer lever, washer and inner lever from
the front case.
20. IF NECESSARY, REPLACE INNER SHIFT LEVER OIL
SEAL
(a) Using a screwdriver, pry out the oil seal from the front
case.
(b) Apply MP grease to the lip of a new oil seal.
(c) Using SST and a hammer, drive in a new oil seal.
SST 09950- 60010 (09951- 00270), 09950- 70010
(09951-07150)
Page 3102 of 3115
TF0864
SST
SST
D02672
D02770
SST
TF0867
TR-12
- TRANSFERTRANSFER ASSEMBLY
1900 Author: Date:
2004 LAND CRUISER (RM1071U)
21. IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL
(a) Using SST and a hammer, drive out the oil seal.
SST 09316-6001 1 (09316-00011)
(b) Apply MP grease to the lip of a new oil seal.
(c) Using SST and a hammer, drive in a new oil seal.
SST 09316-6001 1 (09316-00011, 09316-00031)
22. REMOVE OIL RECEIVER FROM FRONT CASE
Remove the bolt and oil receiver.
23. REMOVE 2 BEARING RACES FROM FRONT CASE
(a) Using SST, remove the bearing race (for the idler gear).
SST 09950- 40011 (09951- 04020, 09952- 04010,
09953- 04030, 09954- 04010, 09955- 04061,
09957-04010), 09950-60010 (09951-00320)
(b) Using a brass bar and hammer, remove the bearing race
(for the output shaft).
Page 3103 of 3115

TR06Y-01
D02673
D02662
SST
D02661
SST
D02672
D04309Socket Wrench
- TRANSFERTRANSFER ASSEMBLY
TR-13
1901 Author: Date:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
1. INSPECT SHIFT FORK NO. 2 AND CLUTCH SLEEVE
CLEARANCE
Using a feeler gauge, measure the clearance between the shift
fork No. 2 and clutch sleeve.
Standard clearance:
0.10 - 0.40 mm (0.0039 - 0.0157 in.)
Maximum clearance:
0.40 mm (0.0157 in.)
2. INSTALL THE BEARING RACE (FOR THE OUTPUT
SHAFT)
Using SST and a press, install the bearing race.
SST 09316-6001 1 (09316-00011, 09316-00031),
09950-60020 (09951-00890)
3. INSTALL THE BEARING RACE (FOR THE IDLER
GEAR)
Using SST and a press, install the bearing race.
SST 09316-6001 1 (09316-00011, 09316-00031),
09950-60020 (09951-00790)
4. INSTALL OIL RECEIVER TO FRONT CASE
Install the oil receiver and bolt.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
5. INSTALL SHIFT OUTER LEVER AND INNER LEVER
(a) Install the shift inner lever, washer and outer lever to the
front case.
(b) Using a pin punch, hammer and socket wrench, tap in the
lever lock pin.
(c) Install the washer and nut to the shift outer lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
Page 3104 of 3115

TF0857
TF0986
D02756
FIPG3 mm (0.12 in.)
D02864A
D02669
TR-14
- TRANSFERTRANSFER ASSEMBLY
1902 Author: Date:
2004 LAND CRUISER (RM1071U)
6. ASSEMBLE SHIFT FORK NO. 1 AND SHIFT FORK NO.
1 SHAFT
(a) Assemble the shift fork No. 1 and shift fork No. 1 shaft.
(b) Using a pin punch and hammer, drive in the slotted spring
pin.
7. INSTALL IDLER GEAR ASSEMBLY WITH CENTER
DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND
SHIFT FORK NO. 1 SHAFT TO FRONT CASE
NOTICE:
Set the shift inner lever into the fork head part of the shift
fork No. 1 securely.
8. INSTALL INPUT SHAFT ASSEMBLY
9. INSTALL 2 BEARING RACES TO REAR CASE
10. ASSEMBLY FRONT CASE AND REAR CASE
(a) Apply FIPG to the front case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(b) Assemble the front case and rear case.
(c) Apply liquid sealer to the ºAº bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Install the 8 bolts.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
11. ASSEMBLE FRONT CASE AND REAR CASE
Using a snap ring expander, install the snap ring to the rear
case.