Toyota Tundra Service Manual: Disassembly

DISASSEMBLY

PROCEDURE

1. REMOVE LOWER TRANSFER CASE PROTECTOR

(a) Remove the 4 bolts and lower transfer case protector.

2. REMOVE WIRING HARNESS CLAMP BRACKET

(a) Remove the 3 bolts and 3 wiring harness clamp brackets.

(b) Disconnect the connector and 3 clamps.

(c) Remove the 2 bolts and wiring harness clamp bracket.

3. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY

4. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (REAR)

(a) Using a chisel and hammer, loosen the staked part of the transfer output shaft nut.

NOTICE:

  • Completely loosen the staked part of the transfer output shaft nut when removing it.
  • Do not damage the threads of the rear transfer output shaft.

(b) Using SST, hold the output shaft companion flange sub-assembly (rear).

SST: 09330-00021

Text in Illustration

*a

Hold

*b

Turn

(c) Using a 30 mm socket wrench, remove the transfer output shaft nut.

(d) Remove the O-ring.

(e) Using SST, remove the output shaft companion flange sub-assembly (rear).

SST: 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04031

09957-04010

09958-04011

Text in Illustration

*a

Hold

*b

Turn

5. REMOVE TRANSFER OUTPUT SHAFT TYPE T OIL SEAL

6. REMOVE TRANSFER INDICATOR SWITCH

7. REMOVE REAR TRANSFER CASE

(a) Using a 40 IP ''TORX PLUS'' socket wrench or T40 ''TORX'' socket wrench, remove the 17 bolts.

(b) Remove the rear transfer case.

HINT:

If necessary, tap the rear transfer case with a plastic-faced hammer to remove it.

8. REMOVE SOLENOID COIL SUB-ASSEMBLY

(a) Disconnect the solenoid coil sub-assembly terminal.

(1) Remove the retainer from the coupler as shown in the illustration.

Text in Illustration

*1

Retainer

*a

Protective Tape

(2) Detach the claw and disconnect the solenoid coil sub-assembly terminal.

(b) Remove the 3 nuts and solenoid coil sub-assembly.

NOTICE:

Be careful not to drop the solenoid coil sub-assembly.

9. REMOVE TRANSFER COVER TYPE T OIL SEAL

(a) Using a screwdriver, remove the transfer cover type T oil seal.

Text in Illustration

*a

Protective Tape

NOTICE:

Do not damage the rear transfer case.

HINT:

Tape the screwdriver tip before use.

10. REMOVE TRANSFER DRIVEN SPROCKET BEARING (REAR)

(a) Using SST, remove the transfer driven sprocket bearing (rear).

SST: 09612-65014

09612-01040

Text in Illustration

*a

Hold

*b

Turn

11. REMOVE REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING

(a) Using a screwdriver, remove the transfer output shaft rear shaft snap ring.

Text in Illustration

*a

Protective Tape

HINT:

Tape the screwdriver tip before use.

(b) Remove the rear transfer output shaft radial ball bearing.

12. REMOVE SOLENOID COVER

(a) Remove the No. 1 transfer output shaft spacer and solenoid cover.

Text in Illustration

*1

No. 1 Transfer Output Shaft Spacer

*2

Solenoid Cover

13. REMOVE TRANSFER SELECT RETURN SPRING

(a) Remove the transfer select return spring.

14. REMOVE TRANSFER HIGH AND LOW SHIFT FORK SHAFT

(a) Remove the transfer high and low shift fork shaft.

15. REMOVE SOLENOID LOCK PLATE WITH NO. 2 TRANSFER GEAR SHIFT FORK

(a) Remove the solenoid lock plate together with the No. 2 transfer gear shift fork.

Text in Illustration

*1

Solenoid Lock Plate

*2

No. 2 Transfer Gear Shift Fork

(b) Remove the No. 2 transfer gear shift fork from the solenoid lock plate.

16. REMOVE CONTROL SELECT SHAFT SUB-ASSEMBLY

(a) Remove the No. 1 transfer gear shift fork from the side of the control select shaft sub-assembly as shown in the illustration. Then remove the control select shaft sub-assembly.

Text in Illustration

*1

No. 1 Transfer Gear Shift Fork

*2

Control Select Shaft Sub-assembly

17. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

(a) Remove the transfer drive sprocket sub-assembly together with the front transfer drive chain and transfer driven sprocket.

Text in Illustration

*1

Transfer Drive Sprocket Sub-assembly

*2

Front Transfer Drive Chain

*3

Transfer Driven Sprocket

NOTICE:

Do not drop the transfer drive sprocket sub-assembly, front transfer drive chain and transfer driven sprocket.

(b) Remove the transfer drive sprocket sub-assembly and transfer driven sprocket from the front transfer drive chain.

18. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY

(a) Using a T25 ''TORX'' socket wrench, remove the bolt and the transfer oil pump body sub-assembly together with the transfer oil tube and transfer oil strainer sub-assembly.

Text in Illustration

*1

Transfer Oil Pump Body Sub-assembly

*2

Transfer Oil Tube

*3

Transfer Oil Strainer Sub-assembly

HINT:

The sleeve does not have to be removed.

The transfer oil strainer sub-assembly comes with the sleeve installed.

(b) Remove the transfer oil tube from the transfer oil pump body sub-assembly.

(c) Remove the transfer oil strainer sub-assembly from the transfer oil tube.

19. REMOVE TRANSFER CASE MAGNET

(a) Remove the transfer case magnet.

20. REMOVE NO. 1 TRANSFER GEAR SHIFT FORK

(a) Remove the No. 1 transfer gear shift fork.

(b) Inspect the gear shift fork pad (See page ).

(c) Remove the 2 gear shift fork pads from the No. 1 transfer gear shift fork.

HINT:

It is not necessary to remove the 2 gear shift fork pads unless they are being replaced.

21. REMOVE REAR TRANSFER OUTPUT SHAFT

(a) Remove the rear transfer output shaft.

22. REMOVE TRANSFER HIGH AND LOW CLUTCH SLEEVE

(a) Remove the transfer high and low clutch sleeve, No. 2 transfer output shaft spacer and transfer lower planetary gear bearing.

Text in Illustration

*1

Transfer High and Low Clutch Sleeve

*2

No. 2 Transfer Output Shaft Spacer

*3

Transfer Lower Planetary Gear Bearing

23. REMOVE TRANSFER LOWER PLANETARY GEAR ASSEMBLY

(a) Remove the transfer lower planetary gear assembly.

(b) Using SST, remove the transfer input gear radial ball bearing.

SST: 09950-00020

SST: 09950-00030

SST: 09950-60010

09951-00480

Text in Illustration

*a

Hold

*b

Turn

24. REMOVE TRANSFER LOWER PLANETARY RING GEAR

(a) Using a screwdriver, remove the transfer lower planetary ring gear hole snap ring.

Text in Illustration

*a

Protective Tape

HINT:

Tape the screwdriver tip before use.

(b) Remove the transfer lower planetary ring gear.

25. REMOVE TRANSFER OIL SEPARATOR

(a) Using a T25 ''TORX'' socket wrench, remove the bolt and transfer oil separator.

26. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (FRONT)

(a) Using a snap ring expander, remove the shaft snap ring and output shaft companion flange sub-assembly (front).

NOTICE:

Do not drop the output shaft companion flange sub-assembly (front).

27. REMOVE NO. 2 TRANSFER CASE OIL SEAL

(a) Using SST, remove the No. 2 transfer case oil seal.

SST: 09612-65014

09612-01020

Text in Illustration

*a

Hold

*b

Turn

28. REMOVE TRANSFER DRIVEN SPROCKET BEARING (FRONT)

(a) Using SST and a press, press out the transfer driven sprocket bearing (front).

SST: 09950-60010

09951-00390

09952-06010

SST: 09950-60020

09951-00730

SST: 09950-70010

09951-07100

29. REMOVE TRANSFER CASE OIL SEAL

(a) Using SST, remove the transfer case oil seal.

SST: 09612-65014

09612-01020

Text in Illustration

*a

Hold

*b

Turn

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