WORKSHEET 5-1

Transfer Case—Disassembly 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: Don’t 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

5W1-1

Driven sprocket 3. High low clutch sleeve 5. Planetary gear set 7. 5W1-2 1. Oil pump TOYOTA Technical Training . Front output shaft 10. Is the vehicle dinghy tow able? Section 2: Component Identification Match the component names listed below with the parts in the illustration.Worksheet 5-1 6. Rear output shaft 8. Silent chain 9. Place the letter that identifies the part on the line in front of the component name. Transfer input shaft 6. Drive sprocket 2. Front drive clutch sleeve 4.

Measure the input shaft and planetary gear thrust bearing axial play: Measurement: Specification: Manual Transmissions & Transaxles – Course 302 5W1-3 . Section 4: Clearance Measurement 1. 4.) 2. Explain how the roll pin should be placed into position. 3. Remove the output shaft. the sprocket should be replaced. Shift forks are secured to the shaft with a roll pin or in some cases with a double roll pin. Remove the oil pump and planetary gear assembly with input shaft. 2.Transfer Case—Disassembly and Component Identification Section 3: Gears. Measure the rear output shaft drive sprocket thrust clearance: Measurement: Specification: (If the clearance exceeds the maximum. STOP proceed only as directed by your instructor. The position of the roll pin slit is essential to preventing the pin from being compressed and working its way from the shift shaft. Shafts and Shift Linkage Removal 1. chain and front drive sprocket. Remove the shift forks and shift fork shafts.

Worksheet 5-1 5W1-4 TOYOTA Technical Training .

I have questions I know I can Topic Comment Identify all gears in the transfer case. Manual Transmissions & Transaxles – Course 302 5W1-5 .Transfer Case—Disassembly and Component Identification Transfer Case—Disassembly & Component Identification Name: Date: Review this sheet as you are doing the Transfer Case—Disassembly & Component Identification worksheet. Additional space is provided under Topic for you to list any other concerns that you would like your instructor to address. Identify all synchronizers in the transfer case. Explain how 4 low and 4 high is engaged. information. Ask the instructor if you have questions regarding the topics provided below. etc. Check each category after viewing the instructor’s presentation and completing the worksheet. Measure output shaft drive sprocket thrust clearances. questions. Measure input shaft and planetary gear thrust bearing axial play. The comments section is provided for your personal comments. Explain how 2WD and 4WD is engaged.

Worksheet 5-1 5W1-6 TOYOTA Technical Training .

Using a dial indicator. Date: Engine Transmission: Worksheet Objectives With this worksheet.Transfer Case—Disassembly and Component Identification WORKSHEET 5-2 Transfer Case—Reassembly Vehicle: Year/Prod. retrieve and apply the needed service information. Tools and Equipment • Vehicle Repair Manual • Hand Tool Set • Dial Indicator and Stand • Micrometer. • Feeler Gauge Section 1: Case Reassembly 1. Assemble rear output shaft Manual Transmissions & Transaxles – Course 302 5W1-7 . retrieve and interpret service specification information from the repair manual.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. you will follow the assembly of a four wheel drive transfer case using the required special tools. 0-1 in. make measurements where appropriate. measure the input shaft axial play: Measurement: Specification: 3. Assemble planetary gear assembly. 2. If the snap ring has a mark designation of H and the axial play is 0..

shift shafts. Install the planetary gear assembly. rear case and extension housing. oil pump. Install the shift forks. 8. chain and driven sprocket. 5W1-8 TOYOTA Technical Training . Remeasure the rear output shaft drive sprocket thrust clearance following assembly: Measurement: Specification: 7. rear output shaft.Worksheet 5-1 6.

Additional space is provided under topic for you to list any other concerns that you would like your instructor to address. information. Manual Transmissions & Transaxles – Course 302 5W1-9 . Use a dial indicator to measure input shaft axial play.Transfer Case—Disassembly and Component Identification Transfer Case—Reassembly Name: Date: Review this sheet as you are doing the Transfer Case—Reassembly worksheet. etc. The comments section is provided for your personal comments. I have questions I know I can Topic Comment Determine shim mark designation from the repair manual shim chart. questions. Check each category after viewing the instructor’s presentation and completing the worksheet. Ask the instructor if you have questions regarding the topics provided below. Explain the application of FIPG to the transfer case sealing surfaces.

Worksheet 5-1 5W1-10 TOYOTA Technical Training .