Page 2953 of 4323
TR0CI±02
F19231
Low Planetary Ring Gear
x5Transfer
Case Cover
Output Shaft Front
Needle Roller Bearing
Oil Pump Gear
Magnet
118 (1,203, 87)
Thrust Bearing Race No. 1
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
Precoated partSnap Ring Case Plug
Breather Oil
Deflector
Front Output Shaft
Companion Flange
Compression Spring
Front Bearing
Retainer
Low Planetary Gear Bearing Low Planetary Gear
Input Gear Stopper
Planetary Carrier Washer
Oil Separator
7.5 (76, 66 in.´lbf)
Oil PumpSnap Ring
Transfer Front
Case
Oil SealSpacer
Snap RingInput Shaft
Ball
Head Pin
O±Ring
Oil Seal Oil Seal
18.6 (190, 14)
18 (184, 13)
11.5 (117, 8)
7.5 (76, 66 in.´lbf)
7.5 (76, 66 in.´lbf)
± TRANSFERTRANSFER ASSEMBLY
TR±7
2945 Author: Date:
2005 SEQUOIA (RM1146U)
TRANSFER ASSEMBLY
COMPONENTS
Page 2954 of 4323
F19232
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
Precoated partTransfer Extension Housing Collar Snap Ring
Transfer Output WasherRear Output Shaft
Companion Flange
24 (245, 18)
Driven Sprocket Front Drive Chain
19 (194, 14)
Shift Shaft Stopper Rear Output Shaft
Sub±assy
Gasket
37 (377, 27)
(Filler Plug) Clamp
28 (286, 21)
x12
Gear Shift Fork No. 1
Rear No. 2 Stopper
Shift ShaftSnap RingTransfer Shift
Actuator
Gasket
Oil Seal High and Low
Clutch Sleeve
Gear Shift Fork No. 2
x5 Front No. 2 Stopper Shift ShaftShift Inter±lock PinFront Drive Shift Fork ShaftTransfer Case Rear Snap Ring20 (204, 15)
No. 1 Plug
37 (377, 27)
(Drain Plug) No. 1 Plug
Oil Seal
12 (122, 9)
20 (204, 15)
118 (1,203, 87)
TR±8
± TRANSFERTRANSFER ASSEMBLY
2946 Author: Date:
2005 SEQUOIA (RM1146U)
Page 2955 of 4323

TR0DF±01
F19238
F19239
F19240
SST
F19241
SST
± TRANSFERTRANSFER ASSEMBLY
TR±9
2947 Author: Date:
2005 SEQUOIA (RM1146U)
DISASSEMBLY
1. REMOVE FRONT BEARING RETAINER
(a) Remove the 5 bolts and front bearing retainer.
HINT:
If necessary, tap on the front bearing retainer with a plastic ham-
mer to remove it.
(b) Using a screwdriver and hammer, remove the oil seal
from the front bearing retainer.
2. REMOVE TRANSFER CASE COVER
Remove the 4 bolts and transfer case cover.
3. REMOVE BREATHER OIL DEFLECTOR
4. REMOVE FRONT OUTPUT SHAFT COMPANION
FLANGE
(a) Using a chisel and hammer, loosen the staked part of the
front output shaft companion flange lock nut.
(b) Using SST to hold the front output shaft companion
flange, remove the output shaft companion flange lock
nut.
SST 09330±00021
(c) Using SST, remove the front output shaft companion
flange.
SST 09950±40011 (09951±04020, 09952±04010,
09953±04030, 09954±04010, 09955±04051,
09957±04010, 09958±04011)
(d) Using a screwdriver and hammer, remove the oil seal
from the front output shaft companion flange.
5. REMOVE REAR OUTPUT SHAFT COMPANION
FLANGE
Remove the rear output shaft companion flange in the same
way as the front output shaft companion flange.
Page 2956 of 4323

F19242
F19243
F19244
F19245
F19246
TR±10
± TRANSFERTRANSFER ASSEMBLY
2948 Author: Date:
2005 SEQUOIA (RM1146U)
6. REMOVE TRANSFER EXTENSION HOUSING
(a) Remove the 5 bolts and transfer extension housing.
HINT:
If necessary, tap on the transfer extension housing with a plas-
tic hammer to remove it.
(b) Using a screwdriver and hammer, remove the oil seal
from the transfer extension housing.
(c) Remove the 2 transfer output washers.
(d) Remove the collar.
7. REMOVE TRANSFER CASE REAR
(a) Remove the 12 bolts and clamp.
(b) Remove the transfer case rear.
HINT:
If necessary, tap on the transfer case rear with a plastic hammer
to remove it.
8. REMOVE GEAR SHIFT FORK NO. 2 AND HIGH AND
LOW CLUTCH SLEEVE
Remove the bolt, gear shift fork No.2 and high and low clutch
sleeve.
9. REMOVE SHIFT SHAFT STOPPER
Remove the bolt and shift shaft stopper.
10. REMOVE FRONT DRIVE SHIFT FORK SHAFT
(a) Turn the front drive shift fork shaft.
(b) Remove the front drive shift fork shaft from the rear case
aligning the cutout with the shift inter±lock pin.
Page 2957 of 4323
F19247
F19248
F19249
F19250
F19251
± TRANSFERTRANSFER ASSEMBLY
TR±11
2949 Author: Date:
2005 SEQUOIA (RM1146U)
(c) Using a magnetic finger, remove the 2 shift inter±lock
pins.
11. REMOVE FRONT NO. 2 STOPPER SHIFT SHAFT
12. REMOVE REAR OUTPUT SHAFT ASSEMBLY, GEAR
SHIFT FORK NO. 1, FRONT DRIVE CHAIN AND DRIV-
EN SPROCKET
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
(b) Using 2 screwdrivers and a hammer, tap out the snap
ring.
(c) Using a snap ring expander, remove the snap ring.
(d) Mount the transfer case rear in a vise.
(e) Using a plastic hammer, carefully tap the transfer case
rear, and remove the rear output shaft assembly together
with the gear shift fork No. 1, front drive chain and driven
sprocket.
Page 2958 of 4323
F19253
F19256
F19257
F19258
F19259
TR±12
± TRANSFERTRANSFER ASSEMBLY
2950 Author: Date:
2005 SEQUOIA (RM1146U)
13. REMOVE REAR NO. 2 STOPPER TRANSFER SHIFT
SHAFT
14. REMOVE TRANSFER SHIFT ACTUATOR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
(b) Remove the 3 bolts and transfer shift actuator.
15. REMOVE OIL SEPARATOR
(a) Remove the 3 bolts and oil separator.
(b) Remove the magnet from the transfer front case.
16. REMOVE OIL PUMP
(a) Remove the 3 bolts and oil pump.
Page 2959 of 4323
F19260
F19261
F19262
F19263
F19264
± TRANSFERTRANSFER ASSEMBLY
TR±13
2951 Author: Date:
2005 SEQUOIA (RM1146U)
(b) Using a screwdriver, remove the O±ring from the oil
pump.
NOTICE:
Be careful not to damage the oil pump.
17. REMOVE OIL PUMP GEAR
18. REMOVE LOW PLANETARY GEAR WITH INPUT
SHAFT
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the low planetary gear with the input shaft from
the transfer front case.
(c) Remove the spacer and output shaft front needle roller
bearing from the input shaft.
(d) Using a screwdriver and hammer, remove the oil seal
from the transfer front case.
Page 2960 of 4323
F19265
F19266
F19267
Front
F19289
F19290
TR±14
± TRANSFERTRANSFER ASSEMBLY
2952 Author: Date:
2005 SEQUOIA (RM1146U)
19. REMOVE LOW PLANETARY GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the input gear stopper, ball and planetary carrier
washer.
(c) Remove the input shaft from the low planetary gear.
(d) Remove the thrust bearing race No. 1 and low planetary
gear bearing.
20. REMOVE CASE PLUG
Remove the case plug, compression spring and head pin from
the transfer front case.
21. REMOVE LOW PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring.
NOTICE:
Be careful not to damage the transfer front case.