PREPARATION – VF4BM TRANSFER PP–53

EQUIPMENT
Dial indicator with magnetic base
Micrometer
Torque wrench
Plastic hammer
Vernier calipers

PP
 PP–54 PREPARATION – VF4BM TRANSFER

LUBRICANT
Item Capacity Classification
API GL-5
Transfer oil 1.4 liters (1.5 US qts, 1.2 lmp. qts)
SAE 75W-90

PP
 PREPARATION – VF4BM TRANSFER PP–55

SSM
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

PP
VF4BM TRANSFER – TRANSFER ASSEMBLY TF–13

REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER SUB-
ASSEMBLY (See page CO-13)
2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY
3. DISCONNECT OXYGEN SENSOR (See page AT-348)
4. REMOVE EXHAUST PIPE ASSEMBLY (See page AT-
348)
5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY TF
(See page PR-14)
6. REMOVE PROPELLER SHAFT ASSEMBLY (See page
PR-3)
7. DRAIN AUTOMATIC TRANSMISSION FLUID (See
page AT-348)
8. DRAIN TRANSFER OIL
9. REMOVE FRONT SUSPENSION MEMBER BRACKET
(See page AT-336)
10. REMOVE FRONT SUSPENSION MEMBER BRACKET
LH (See page AT-348)
11. REMOVE TRANSMISSION OIL FILTER TUBE SUB-
ASSEMBLY
12. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE
(See page AT-348)
13. REMOVE NO. 1 OIL COOLER INLET TUBE (See page
AT-348)
14. DISCONNECT TRANSMISSION CONTROL CABLE
ASSEMBLY (See page AT-349)
15. REMOVE NO. 1 TRANSMISSION CONTROL CABLE
BRACKET (See page AT-349)
16. REMOVE TRANSFER CASE LOWER PROTECTOR
(a) Remove the 4 bolts and transfer case lower
protector.
17. SUPPORT AUTOMATIC TRANSMISSION WITH
TRANSFER (See page AT-349)
18. REMOVE NO. 3 CROSSMEMBER SUB-ASSEMBLY
(See page AT-349)
19. DISCONNECT CONNECTOR
F043499

20. DISCONNECT WIRE HARNESS

21. REMOVE FLYWHEEL HOUSING UNDER COVER (See
page AT-349)
22. REMOVE AUTOMATIC TRANSMISSION WITH
TRANSFER (See page AT-350)
 TF–14 VF4BM TRANSFER – TRANSFER ASSEMBLY

23. REMOVE TRANSFER ASSEMBLY

(a) Remove the 8 bolts and 2 clamps.
(b) Remove the transfer from the automatic
transmission.

TF F043500
 SS–48 SERVICE SPECIFICATIONS – VF4BM TRANSFER

TORQUE SPECIFICATIONS
Part Tightened N*m kgf cm ft*lbf
Transfer case lower protector x Transfer 18 184 13
Transfer x Transfer adaptor 24 240 17
Front bearing retainer sub-assembly x Front case 11.5 117 8
Transfer case cover sub-assembly x Front case 18 185 13
Output shaft companion flange sub-assembly lock nut 118 1,200 87
Extension housing sub-assembly rear x Case rear 12 120 9

SS Front case x Case rear 28 285 21

Gear shift fork No. 2 x Transfer shift actuator assembly 24 245 18
CTR differential lock fork sub-assembly x Transfer shift actuator
24 245 18
assembly
Transfer shift actuator assembly x Case rear 20 200 14
Case No. 1 plug (Filler plug) x Case rear 37 380 27
Case No. 1 plug (Drain plug) x Case rear 37 380 27
Oil separator sub-assembly x Case rear 7.8 80 69 in.*lbf
Oil separator sub-assembly x Case rear 7.8 80 69 in.*lbf
Transfer case plug x Front case 18.6 190 14
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–15

DISASSEMBLY
1. REMOVE HOSE
2. TEST TRANSFER RH BEARING RETAINER SUB-
ASSEMBLY
(a) Remove the 5 bolts and front bearing retainer sub-
assembly.
HINT:
If necessary, tap the front bearing retainer sub-
assembly with a plastic hammer to remove it.
3. REMOVE TRANSFER COVER TYPE T OIL SEAL
TF
(a) Using a screwdriver and hammer, remove the oil
F043427
seal from the front bearing retainer sub-assembly.
4. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY
(a) Remove the 4 bolts and the case cover sub-
assembly.
5. REMOVE BREATHER OIL DEFLECTOR SUB-
ASSEMBLY

F043428

6. REMOVE OUTPUT SHAFT COMPANION FLANGE

SUB-ASSEMBLY
(a) Using a chisel and hammer, loosen the staked part
of the output shaft companion flange lock nut.
(b) Using SST to hold the output shaft companion
flange, remove the output shaft companion flange
lock nut.
SST 09330-00021
SST
F043429E01

(c) Using SST, remove the output shaft companion

flange sub-assembly.
SST 09950-40011 (09951-04020, 09952-04010,
09953-04030, 09954-04010, 09955-04051,
09957-04010, 09958-04011)
7. REMOVE TRANSFER OUTPUT SHAFT COMPANION
FLANGE OIL SEAL
SST (a) Using a screwdriver and hammer, remove the
companion flange oil seal from the output shaft
F043430E01
companion flange sub-assembly.
8. REMOVE OUTPUT SHAFT COMPANION FLANGE
SUB-ASSEMBLY
(a) Remove the rear output shaft companion flange
sub-assembly using the same procedure as for the
front output shaft companion flange sub-assembly.
SST 09330-00021, 09950-40011 (09951-04020,
09952-04010, 09953-04030, 09954-04010,
09955-04051, 09957-04010, 09958-04011)
 TF–16 VF4BM TRANSFER – TRANSFER ASSEMBLY

9. REMOVE TRANSFER OUTPUT SHAFT COMPANION

FLANGE OIL SEAL
(a) Using a screwdriver and hammer, remove the
companion flange oil seal from the output shaft
companion flange sub-assembly.
10. REMOVE FRONT TRANSFER EXTENSION HOUSING
SUB-ASSEMBLY
(a) Remove the 5 bolts and extension housing sub-
assembly.
TF HINT:
If necessary, tap the extension housing sub-
assembly with a plastic hammer to remove it.

F043431

11. REMOVE TRANSFER EXTENSION HOUSING TYPE T

OIL SEAL
(a) Using a screwdriver and hammer, remove the
extension housing type T oil seal.
12. REMOVE TRANSFER OUTPUT WASHER
13. REMOVE COLLAR

F043432

14. REMOVE TRANSFER REAR CASE

(a) Remove the 12 bolts and clamp.
(b) Remove the transfer rear case.
HINT:
If necessary, tap the transfer rear case with a plastic
hammer to remove it.

F043433

15. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK

WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE
(a) Remove the bolt, gear shift fork No. 2 and high and
low clutch sleeve.

F043434
VF4BM TRANSFER – TRANSFER ASSEMBLY TF–17

16. REMOVE CTR DIFFERENTIAL LOCK FORK SUB-

ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE
(a) Using 2 screwdrivers and hammer, tap out the snap
ring.

F043502
TF
(b) Remove the bolt, CTR differential lock fork sub-
assembly and front drive clutch sleeve.

F043503

17. REMOVE REAR OUTPUT SHAFT SUB-ASSEMBLY,

FRONT DRIVE CHAIN AND DRIVEN SPROCKET
SUB-ASSEMBLY
(a) Mount the transfer case rear in a vise.
(b) Using a plastic hammer, carefully tap the a transfer
case rear, and remove the rear output shaft sub
assembly together with front drive chain and driven
sprocket sub-assembly.

F043504

(c) Remove the rear output shaft sub-assembly, front

drive chain and driven sprocket sub assembly.

F043505

18. REMOVE TRANSFER DRIVEN SPROCKET BEARING

(a) Using a press, remove the driven sprocket bearing.

F043523
 TF–18 VF4BM TRANSFER – TRANSFER ASSEMBLY

19. REMOVE TRANSFER INPUT GEAR RADIAL BALL

Steel Bar BEARING
(a) Using SST, a press and steel bar, remove the
SST transfer input gear radial ball bearing.
SST 09555-55010

TF F043524E02

20. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY

(a) Using 2 screwdrivers and a hammer, tap out the 2
snap rings.

F043506

(b) Remove the 3 bolts and transfer shift actuator

assembly.
21. REMOVE TRANSFER CASE NO.1 PLUG
(a) Remove the transfer case No. 1 plug (filler plug) and
gasket.
22. REMOVE TRANSFER CASE NO.1 PLUG
(a) Remove the transfer case No. 1 plug (drain plug)
and gasket.
F043445

23. REMOVE TRANSFER OIL SEPARATOR SUB-

ASSEMBLY
(a) Remove the 3 bolts and oil separator sub-assembly.
24. REMOVE TRANSFER CASE MAGNET

F043446

25. REMOVE TRANSFER OIL PUMP BODY SUB-

ASSEMBLY
(a) Remove the 3 bolts and oil pump body sub-
assembly.

F043447
VF4BM TRANSFER – TRANSFER ASSEMBLY TF–19

26. REMOVE TRANSFER OIL PUMP BODY O-RING

(a) Using a screwdriver, remove the oil pump body O-
ring.

F043462
TF
27. REMOVE TRANSFER OIL PUMP GEAR
(a) Remove the transfer oil pump gear.

F043448

28. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH

INPUT SHAFT SUB-ASSEMBLY
(a) Using a snap ring expander, remove the snap ring.

F043449

(b) Remove the low planetary gear assembly with input

shaft assembly.

Q007221

29. REMOVE TRANSFER OUTPUT SHAFT SPACER

(a) Remove the transfer output shaft spacer.
30. REMOVE TRANSFER OUTPUT SHAFT FRONT
NEEDLE ROLLER BEARING
31. REMOVE TRANSFER CASE OIL SEAL
(a) Using a screwdriver and hammer, remove the
transfer case oil seal.

F043451
 TF–20 VF4BM TRANSFER – TRANSFER ASSEMBLY

32. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT

SNAP RING
(a) Using a snap ring expander, remove the input gear
stopper shaft snap ring.

TF F043452

33. REMOVE TRANSFER INPUT GEAR STOPPER

(a) Remove the transfer input gear stopper.
34. REMOVE TRANSFER INPUT GEAR STOPPER BALL
35. REMOVE MANUAL TRANSFER PLANETARY
CARRIER WASHER

F043453

36. REMOVE TRANSFER INPUT SHAFT

(a) Remove the transfer input shaft.

Front 37. REMOVE TRANSFER NO. 1 THRUST BEARING

RACE
38. REMOVE TRANSFER LOW PLANETARY GEAR
BEARING

F043454E01

39. REMOVE TRANSFER NO. 1 INPUT SHAFT SEAL

RING
(a) Remove the 2 seal rings.

F043525E01

40. INSPECT TRANSFER INPUT SHAFT

(a) Using a micrometer, measure the outer diameter of
the input shaft journal surface.
Minimum diameter:
47.59 mm (1.8736 in.)
If the outer diameter is less than the minimum,
replace the input shaft.

F043458
VF4BM TRANSFER – TRANSFER ASSEMBLY TF–21

(b) Using a dial indicator, measure the inside diameter

of the input shaft bushing.
Maximum diameter:
48.14 mm (1.8953 in.)
If the inside diameter exceeds the maximum,
replace the input shaft.

F043459
TF
41. INSPECT PLANETARY PINION GEAR THRUST
CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance
of the planetary pinion gear.
Standard clearance:
0.11 to 0.84 mm (0.0043 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the
F043465 planetary gear assembly.

42. INSPECT PLANETARY PINION GEAR RADIAL

CLEARANCE
(a) Using a dial indicator, measure the radial clearance
of the planetary pinion gear.
Standard clearance:
0.009 to 0.038 mm (0.0004 to 0.0015 in.)
Maximum clearance:
0.038 mm (0.0015 in.)
If the clearance exceeds the maximum, replace the
F043466 planetary gear assembly.

43. REMOVE TRANSFER INPUT SHAFT BEARING

(a) Using a snap ring expander, remove the snap ring.
SST (b) Using SST and a press, remove the input shaft
bearing.
SST 09554-30011, 09555-55010

F043467E02

44. REMOVE TRANSFER LOW PLANETARY GEAR

SPLINE PIECE
(a) Using a screwdriver, remove the snap ring.
(b) Remove the low planetary gear spline piece.

F043507
 TF–22 VF4BM TRANSFER – TRANSFER ASSEMBLY

45. REMOVE TRANSFER LOW PLANETARY GEAR

BEARING
(a) Using SST, remove the low planetary gear bearing.
SST 09612-65014 (09612-01030, 09612-01050)
NOTICE:
Hang SST securely to the clearance between the
bearing and the low planetary gear.
SST

TF F043526E02

46. INSPECT DRIVE SPROCKET THRUST CLEARANCE

(a) Using a feeler gauge, measure the drive sprocket
thrust clearance.
Standard clearance:
0.15 to 0.24 mm (0.0059 to 0.0094 in.)
Maximum clearance:
0.24 mm (0.0094 in.)
If the clearance exceeds the maximum, replace the
drive sprocket.
F044049

47. INSPECT DRIVE SPROCKET RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance
of the drive sprocket.
Standard clearance:
0.01 to 0.06 mm (0.0004 to 0.0024 in.)
Maximum clearance:
0.06 mm (0.0024 in.)
If the clearance exceeds the maximum, replace the
drive sprocket, output shaft rear or needle roller
F044050 bearing.

48. REMOVE TRANSFER LOW PLANETARY RING GEAR

HOLE SNAP RING
(a) Using a snap ring expander, remove the snap ring.
49. REMOVE NO. 2 TRANSFER OUTPUT SHAFT
SPACER
50. REMOVE TRANSFER OUTPUT SHAFT SPACER
BALL
51. REMOVE CENTER DIFFERENTIAL CASE
F044051

52. REMOVE TRANSFER CLUTCH HUB

(a) Remove the transfer clutch hub.
53. REMOVE TRANSFER OUTPUT SHAFT FRONT
NEEDLE ROLLER BEARING
54. REMOVE TRANSFER OUTPUT SHAFT PLATE
WASHER

F043510
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–23

55. REMOVE TRANSFER OUTPUT SHAFT REAR

SST RADIAL BALL BEARING
(a) Using SST and a press, remove the output shaft
rear radial ball bearing.
SST 09555-55010

F043475E01
TF
56. REMOVE NO. 1 TRANSFER OUTPUT SHAFT
SPACER
(a) Remove the transfer output shaft spacer.
57. REMOVE TRANSFER DRIVE SPROCKET SUB-
ASSEMBLY
58. REMOVE TRANSFER DRIVE SPROCKET BEARING
59. REMOVE TRANSFER OUTPUT SHAFT PLATE
WASHER
F043476

60. INSPECT TRANSFER OUTPUT SHAFT REAR

(a) Using a micrometer, measure the outer diameter of
D C B A the output shaft rear journal surface.
Standard diameter:
Part A:
27.98 to 27.99 mm (1.1016 to 1.1020 in.)
Part B:
31.98 to 32.00 mm (1.2591 to 1.2598 in.)
Part C:
F043511E01 34.98 to 35.00 mm (1.3772 to 1.3780 in.)
Part D:
36.98 to 37.00 mm (1.4559 to 1.4567 in.)
Minimum diameter:
Part A:
27.98 mm (1.1016 in.)
Part B:
31.98 mm (1.2591 in.)
Part C:
34.98 mm (1.3772 in.)
Part D:
36.98 mm (1.4559 in.)
If the outer diameter is less than the minimum,
replace the output shaft rear.
 TF–24 VF4BM TRANSFER – TRANSFER ASSEMBLY

61. INSPECT HIGH AND LOW CLUTCH SLEEVE AND

GEAR SHIFT FORK NO. 2 CLEARANCE
(a) Using vernier calipers, measure the thickness of the
gear shift fork No. 2 claw.
Thickness:
10 mm (0.3937 in.)
(b) Using vernier calipers, measure the groove of the
high and low clutch sleeve.
Distance:
10.5 mm (0.4134 in.)
TF F043481

(c) Calculate a clearance between the high and low

clutch sleeve and gear shift fork No. 2 clearance.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the
high and low clutch sleeve or gear shift fork No. 2.
62. INSPECT FRONT DRIVE CLUTCH SLEEVE AND CTR
DIFFERENTIAL LOCK FORK SUB-ASSEMBLY
CLEARANCE
(a) Using vernier calipers, measure the thickness of the
CTR differential lock fork clow.
Thickness:
10 mm (0.3937 in.)
(b) Using vernier calipers, measure the groove of the
front drive clutch sleeve.
F043483 Distance:
10.5 mm (0.4134 in.)
(c) Calculate a clearance between the front drive clutch
sleeve and CTR differential lock fork.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the
front drive clutch sleeve or CTR differential lock fork.
63. INSPECT CENTER DIFFERENTIAL CASE AND HIGH
AND LOW CLUTCH SLEEVE
(a) Check that the tip of the spline gear of the front drive
clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center
differential case and check that the front drive clutch
sleeve moves smoothly.

F043493
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–25

64. INSPECT CENTER DIFFERENTIAL CASE AND

FRONT DRIVE CLUTCH SLEEVE
(a) Check that the tip of the spline gear of the front drive
clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center
differential case and check that the front drive clutch
sleeve moves smoothly.

F044398
TF
65. REMOVE TRANSFER CASE PLUG
(a) Remove the transfer case plug.
66. REMOVE COMPRESSION SPRING
67. REMOVE WITH HEAD PIN

F043455

68. REMOVE TRANSFER LOW PLANETARY RING GEAR

(a) Using a screwdriver, remove the snap ring.

F043456

(b) Remove the low planetary ring gear from the front
case.

Front

F043457E01

INSPECTION
1. INSPECT TRANSFER INPUT SHAFT
(a) Using a micrometer, measure the outer diameter of
the input shaft journal surface.
Minimum diameter:
47.59 mm (1.8736 in.)
If the outer diameter is less than the minimum,
replace the input shaft.
F043458
 TF–26 VF4BM TRANSFER – TRANSFER ASSEMBLY

(b) Using a dial indicator, measure the inside diameter

of the input shaft bushing.
Maximum diameter:
48.14 mm (1.8593 in.)
If the inside diameter exceeds the maximum,
replace the input shaft.

TF Q007293

2. INSPECT PLANETARY PINION GEAR THRUST

CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance
of the planetary pinion gear.
Standard clearance:
0.11 to 0.84 mm (0.0043 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the
F043465 planetary gear assembly.

3. INSPECT PLANETARY PINION GEAR RADIAL

CLEARANCE
(a) Using a dial indicator, measure the radial clearance
of the planetary pinion gear.
Standard clearance:
0.009 to 0.038 mm (0.0004 to 00015 in.)
Maximum clearance:
0.038 mm (0.0015 in.)
If the clearance exceeds the maximum, replace the
F043466 planetary gear assembly.

4. INSPECT DRIVE SPROCKET THRUST CLEARANCE

(a) Using a feeler gauge, measure the thrust clearance
of the drive sprocket.
Standard clearance:
0.15 to 0.24 mm (0.0059 to 0.0094 in.)
Maximum clearance:
0.24 mm (0.0094 in.)
If the clearance exceeds the maximum, replace the
drive sprocket.
F044049

5. INSPECT DRIVE SPROCKET RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance
of the drive sprocket.
Standard clearance:
0.01 to 0.06 mm (0.0004 to 0.0024 in.)
Maximum clearance:
0.06 mm (0.0024 in.)
If the clearance exceeds the maximum, replace the
drive sprocket, rear output shaft or needle roller
F044050 bearing.
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–27

6. INSPECT TRANSFER OUTPUT SHAFT REAR

(a) Using a micrometer, measure the outer diameter of
D C B A the output shaft rear journal surface.
Standard diameter:
Part A:
27.98 to 27.99 mm (1.1016 to 1.1020 in.)
Part B:
31.98 to 32.00 mm (1.2591 to 1.2598 in.)
Part C:
34.98 to 35.00 mm (1.3772 to 1.3780 in.)
F043511E01

Part D: TF
36.98 to 37.00 mm (1.4559 to 1.4567 in.)
Minimum diameter:
Part A:
27.98 mm (1.1016 in.)
Part B:
31.98 mm (1.2591 in.)
Part C:
34.98 mm (1.3772 in.)
Part D:
36.98 mm (1.4559 in.)
If the outer diameter is less than the minimum,
replace the output shaft rear.
7. INSPECT HIGH AND LOW CLUTCH SLEEVE AND
GEAR SHIFT FORK NO. 2 CLEARANCE
(a) Using vernier calipers, measure the thickness of the
gear shift fork No. 2 claw.
Thickness:
10 mm (0.3937 in.)
(b) Using vernier calipers, measure the groove of the
high and low clutch sleeve.
Distance:
F043481 10.5 mm (0.4134 in.)
(c) Calculate a clearance between the high and low
clutch sleeve and gear shift fork No. 2 clearance.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the
high and low clutch sleeve or gear shift fork No. 2.
8. INSPECT FRONT DRIVE CLUTCH SLEEVE AND CTR
DIFFERENTIAL LOCK FORK SUB-ASSEMBLY
CLEARANCE
(a) Using vernier calipers, measure the thickness of the
CTR differential lock fork clow.
Thickness:
10 mm (0.3937 in.)
(b) Using vernier calipers, measure the groove of the
front drive clutch sleeve.
F043483 Distance:
10.5 mm (0.4134 in.)
 TF–28 VF4BM TRANSFER – TRANSFER ASSEMBLY

(c) Calculate a clearance between the front drive clutch

sleeve and CTR differential lock fork.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the
front drive clutch sleeve or CTR differential lock fork.
9. INSPECT CENTER DIFFERENTIAL CASE AND HIGH
TF AND LOW CLUTCH SLEEVE
(a) Check that the tip of the spline gear of the front drive
clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center
differential case and check that the front drive clutch
sleeve moves smoothly.

F043493

10. INSPECT CENTER DIFFERENTIAL CASE AND

FRONT DRIVE CLUTCH SLEEVE
(a) Check that the tip of the spline gear of the front drive
clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center
differential case and check that the front drive clutch
sleeve moves smoothly.

F044398
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–29

REASSEMBLY
1. INSTALL TRANSFER LOW PLANETARY RING GEAR
(a) Install the low planetary ring gear to the front case.
(b) Using a screwdriver, install the snap ring.

TF

F043456

2. INSTALL WITH HEAD PIN

(a) Install w/ head pin.
3. INSTALL COMPRESSION SPRING
4. INSTALL TRANSFER CASE PLUG
Torque: 18.6 N*m (190 kgf*cm, 14 ft.*lbf)

F043455

5. INSTALL TRANSFER OUTPUT SHAFT PLATE

WASHER
(a) Install the transfer output shaft plate washer.
6. INSTALL TRANSFER DRIVE SPROCKET BEARING
7. INSTALL TRANSFER DRIVE SPROCKET SUB-
ASSEMBLY
8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER
F043476

9. INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL

BALL BEARING
(a) Using SST and a press, install a new output shaft
rear radial ball bearing.
SST Rear
SST 09316-60011 (09316-00011, 09316-00071)
NOTICE:
Install the output shaft rear radial ball bearing so
that the bearing snap ring groove face to the
rear.
F044046E01
 TF–30 VF4BM TRANSFER – TRANSFER ASSEMBLY

10. INSTALL TRANSFER OUTPUT SHAFT PLATE

WASHER
(a) Install the transfer output shaft plate washer.
11. INSTALL TRANSFER OUTPUT SHAFT FRONT
NEEDLE ROLLER BEARING
12. INSTALL TRANSFER CLUTCH HUB

TF F043510

13. INSTALL CENTER DIFFERENTIAL CASE

(a) Install the center differential case.
14. INSTALL TRANSFER OUTPUT SHAFT SPACER
BALL
15. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.2
16. INSTALL TRANSFER LOW PLANETARY RING GEAR
HOLE SNAP RING
(a) Using a snap ring expender, install the snap ring.
F044051

17. INSTALL DRIVE SPROCKET RADIAL CLEARANCE

18. INSPECT DRIVE SPROCKET THRUST CLEARANCE
19. INSTALL TRANSFER INPUT SHAFT BEARING
(a) Using SST and a press, install a new bearing with
SST the groove facing forward.
SST 09223-15020, 09515-30010, 09950-70010
(09951-07100)

SST

F043513E01

20. INSTALL TRANSFER LOW PLANETARY GEAR

SPLINE PIECE
(a) Using a screwdriver, install the spline piece and low
planetary gear with the snap ring.

F043507
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–31

21. INSTALL TRANSFER LOW PLANETARY GEAR

7.7 to 8.3mm BEARING
(0.303 to 0.327 in.) (a) Using SST and a press, tap in a new low planetary
gear bearing.
SST 09950-60010 (09951-00570), 09950-70010
(09951-07100)
Press in depth:
7.7 to 8.3 mm (0.303 to 0.327 in.)
SST
F043469E01
TF
22. INSTALL TRANSFER INPUT BEARING SHAFT SNAP
RING
(a) Select a snap ring that allows the minimum axial
play.

Mark Thickness mm (in.)

1 1.45 to 1.50 (0.0571 to 0.0591)
2 1.50 to 1.55 (0.0591 to 0.0610)
3 1.55 to 1.60 (0.0610 to 0.0630)
F043468 4 1.60 to 1.65 (0.0630 to 0.0650)
5 1.65 to 1.70 (0.0650 to 0.0669)

(b) Using a snap ring expander, install a new snap ring.

23. INSTALL TRANSFER NO. 1 INPUT SHAFT SEAL
RING
(a) Apply gear oil to the oil seal ring.
(b) Engage securely to eliminate clearance as shown in
the illustration.

F043460

24. INSTALL TRANSFER LOW PLANETARY GEAR

BEARING
(a) Install the transfer low planetary gear bearing.
Front
25. INSTALL NO. 1 TRANSFER THRUST BEARING RACE
26. INSTALL TRANSFER INPUT SHAFT

F043454E01
 TF–32 VF4BM TRANSFER – TRANSFER ASSEMBLY

27. INSTALL MANUAL TRANSFER PLANETARY

CARRIER WASHER
(a) Install the manual transfer planetary carrier washer.
28. INSTALL TRANSFER INPUT GEAR STOPPER BALL
29. INSTALL TRANSFER INPUT GEAR STOPPER

TF F043453

30. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT

SNAP RING
(a) Select an input gear stopper shaft snap ring that
allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) axial
play.

Mark Thickness mm (in.)

A 2.10 to 2.15 (0.0827 to 0.0846)
B 2.15 to 2.20 (0.0846 to 0.0866)
F043514 C 2.20 to 2.25 (0.0866 to 0.0886)
D 2.25 to 2.30 (0.0886 to 0.0906)
E 2.30 to 2.35 (0.0906 to 0.0925)
F 2.35 to 2.40 (0.0925 to 0.0945)
G 2.40 to 2.45 (0.0945 to 0.0965)
H 2.45 to 2.50 (0.0965 to 0.0984)
J 2.50 to 2.55 (0.0984 to 0.1004)
K 2.55 to 2.60 (0.1004 to 0.1024)
L 2.60 to 2.65 (0.1024 to 0.1043)
M 2.65 to 2.70 (0.1043 to 0.1063)
N 2.70 to 2.75 (0.1063 to 0.1083)
P 2.75 to 2.80 (0.1083 to 0.1102)
Q 2.80 to 2.85 (0.1102 to 0.1122)
R 2.85 to 2.90 (0.1122 to 0.1142)
S 2.90 to 2.95 (0.1142 to 0.1161)
T 2.95 to 3.00 (0.1161 to 0.1181)
U 3.00 to 3.05 (0.1181 to 0.1201)

(b) Using a snap ring expander, install the new input

gear stopper shaft snap ring.

Q007289
VF4BM TRANSFER – TRANSFER ASSEMBLY TF–33

31. INSTALL TRANSFER CASE OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal until
SST
its surface is flush with the case upper surface.
SST 09316-60011 (09316-00011)
(b) Coat the lip of the oil seal with MP grease.

F043515E01
TF
32. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH
INPUT SHAFT SUB-ASSEMBLY
(a) Install the low planetary gear assembly with input
shaft sub-assembly.

F043450

(b) Using a snap ring expander, install the shaft snap

ring.

F043449

33. INSTALL TRANSFER OIL PUMP GEAR

(a) Install transfer oil pump gear.

F043448

34. INSTALL TRANSFER OIL PUMP BODY O-RING

(a) Coat a new O-ring with gear oil and install it to the
oil pump body.

F043463E01
 TF–34 VF4BM TRANSFER – TRANSFER ASSEMBLY

35. INSTALL TRANSFER OIL PUMP BODY SUB-

ASSEMBLY
(a) Install the oil pump body sub-assembly with the 3
bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
36. INSTALL TRANSFER CASE MAGNET

TF F043447

37. INSTALL TRANSFER OIL SEPARATOR SUB-

ASSEMBLY
(a) Install the oil separator sub-assembly with the 3
bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
38. INSTALL TRANSFER CASE PLUG
(a) Install the case plug No. 1 (filler plug) and a new
gasket.
Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf)
F043446

39. INSTALL TRANSFER CASE PLUG

(a) Install the case plug (drain plug) and a new gasket.
Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf)
40. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY
(a) Install the shift actuator assembly with the 3 bolts.
Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
(b) Using a screwdriver and hammer, drive in the snap
ring.

F043445

41. INSTALL TRANSFER INPUT GEAR RADIAL BALL

BEARING
(a) Using SST and a press, install a new input gear
radial ball bearing.
SST 09316-60011 (09316-00031)
SST

F043464E02
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–35

42. INSTALL TRANSFER DRIVEN SPROCKET BEARING

(a) Using a press, install a new driven sprocket bearing.

F044041
TF
43. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY,
FRONT DRIVE CHAIN AND DRIVEN SPROCKET
SUB-ASSEMBLY
(a) Install the rear output shaft sub-assembly, and drive
sprocket to the front drive chain.

F043442

(b) Install the rear output shaft sub-assembly, front

drive chain and driven sprocket sub-assembly to the
rear case.
HINT:
Check that the rear output shaft sub-assembly and
driven sprocket sub-assembly turn lightly.

F043441

44. INSTALL CTR DIFFERENTIAL LOCK FORK SUB-

Front ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE
(a) Install the CTR differential lock fork sub-assembly
and front drive clutch sleeve.
(b) Install the bolt.
Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
(c) Using a screwdriver and hammer, drive in the snap
ring.

F043519E01

45. INSTALL TRANSFER GEAR SHIFT FORK NO. 2 WITH

TRANSFER HIGH AND LOW CLUTCH SLEEVE
Front (a) Install the gear shift fork No. 2 and high and low
clutch sleeve.
(b) Install the bolt.
Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
46. INSTALL TRANSFER OUTPUT SHAFT SPACER
47. INSTALL TRANSFER OUTPUT SHAFT FRONT
F044401E01 NEEDLE ROLLER BEARING
 TF–36 VF4BM TRANSFER – TRANSFER ASSEMBLY

48. INSTALL TRANSFER CASE REAR

(a) Apply FIPG to the case rear, as shown.
FIPG:
FIPG Part No. 08826-00090, THREE BOND 1281 or
equivalent

TF F043488E01

(b) Install the clamp and case rear with the 12 bolts.
Torque: 28 N*m (285 kgf*cm, 21 ft.*lbf)

F043433

49. INSTALL COLLAR

(a) Install collar.
50. INSTALL TRANSFER OUTPUT WASHER

F043432

51. INSTALL TRANSFER EXTENSION HOUSING TYPE T

OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal
SST until its surface is flush with the housing upper
surface.
SST 09223-46011, 09631-32020
(b) Coat the lip of the oil seal with MP grease.

F043516E02

52. INSTALL TRANSFER EXTENSION HOUSING SUB-

ASSEMBLY REAR
(a) Apply FIPG to the extension housing sub-assembly,
as shown in the illustration.
FIPG FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(b) Apply sealant to the bolt threads.
Sealant:
F043489E01 Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–37

(c) Install the extension housing sub-assembly with the

5 bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)

F043431
TF
53. INSTALL TRANSFER OUTPUT SHAFT COMPANION
FLANGE OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal
SST (front side).
SST 09950-60010 (09951-00320), 09950-70010
(09951-07100)
(b) Coat the lip of the oil seal with MP grease.
54. INSTALL TRANSFER OUTPUT SHAFT COMPANION
FLANGE OIL SEAL
F043517E02
(a) Drive in a new output shaft companion flange oil
seal using the same procedure as for the oil seal.
SST 09950-60010 (09951-00320), 09950-70010
(09951-07100)
55. INSTALL OUTPUT SHAFT COMPANION FLANGE
SUB-ASSEMBLY
Front: Rear: (a) Install the companion flange sub-assembly (front
side) onto the drive sprocket sub-assembly.
(b) Using SST to hold the companion flange, install a
new companion flange lock nut.
SST 09330-00021
Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf)
(c) Using a chisel and hammer, stake the companion
flange lock nut.
56. INSTALL OUTPUT SHAFT COMPANION FLANGE
SUB-ASSEMBLY
SST (a) Using SST, install the companion flange sub-
assembly using the same procedure as for the
companion flange sub-assembly (rear side).
Torque: 118 N*m (1200 kgf*cm, 87 ft.*lbf)
SST 09330-00021
57. INSTALL BREATHER OIL DEFLECTOR

F044048E02
 TF–38 VF4BM TRANSFER – TRANSFER ASSEMBLY

58. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY

(a) Install the case cover sub-assembly with the 4 bolts.
Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)

TF F043428

59. INSTALL TRANSFER COVER TYPE T OIL SEAL

(a) Using SST and a hammer, drive in a new oil seal
until its surface is flush with the retainer upper
SST surface.
(b) Coat the lip of the oil seal with MP grease.
SST 09950-60010 (09951-00590), 09950-70010
(09951-07100)

F043518E02

60. INSTALL TRANSFER BEARING RETAINER SUB-

ASSEMBLY
(a) Apply FIPG to the front bearing retainer sub-
assembly, as shown in the illustration.
FIPG FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(b) Apply sealant to the bolt threads.
Sealant:
F043490E01 Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Install the front bearing retainer sub-assembly with
the 5 bolts.
Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf)
61. INSTALL HOSES

F043427

INSTALLATION
1. INSTALL TRANSFER ASSEMBLY
(a) Install the transfer assembly with the 8 bolts.
Torque: 24 N*m (240 kgf*cm, 17 ft.*lbf)
NOTICE:
Take care not to damage the adaptor rear oil seal
with the transfer input gear spline.
2. INSTALL AUTOMATIC TRANSMISSION WITH
F043500 TRANSFER (See page EM-67)
VF4BM TRANSFER – TRANSFER ASSEMBLY TF–39

3. INSTALL FLYWHEEL HOUSING UNDER COVER (See

page AT-351)
4. CONNECT WIRE HARNESS
5. CONNECT CONNECTOR
6. INSTALL NO. 3 FRAME CROSSMEMBER SUB-
ASSEMBLY (See page AT-351)
7. INSTALL TRANSFER CASE LOWER PROTECTOR
(a) Install the transfer case lower protector with the 4
bolts. TF
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
8. INSTALL NO. 1 TRANSFER CONTROL CABLE
BRACKET (See page AT-351)
9. CONNECT TRANSMISSION CONTROL CABLE
ASSEMBLY (See page AT-351)
F043499
10. INSTALL NO. 1 OIL COOLER INLET TUBE (See page
AT-352)
11. CONNECT NO. 1 OIL COOLER OUTLET TUBE (See
page AT-352)
12. INSTALL TRANSMISSION OIL FILLER TUBE SUB-
ASSEMBLY (See page AT-352)
13. INSTALL FRONT SUSPENSION MEMBER BRACKET
LH (See page AT-338)
14. INSTALL FRONT SUSPENSION MEMBER BRACKET
(See page AT-352)
15. ADD TRANSFER OIL
HINT:
(See page TF-3)
16. ADD AUTOMATIC TRANSMISSION FLUID (See page
AT-353)
17. INSPECT AUTOMATIC TRANSMISSION FLUID
18. INSTALL PROPELLER SHAFT ASSEMBLY (See page
PR-12)
19. INSTALL PROPELLER SHAFT ASSEMBLY FRONT
(See page PR-19)
20. INSTALL EXHAUST PIPE ASSEMBLY (See page AT-
352)
21. CONNECT OXYGEN SENSOR (See page AT-353)
22. INSTALL ENGINE UNDER COVER ASSEMBLY REAR
23. INSTALL NO. 1 ENGINE UNDER COVER SUB-
ASSEMBLY
24. INSPECT AUTOMATIC TRANSMISSION FLUID
HINT:
(See page AT-305)
25. INSPECT SHIFT LEVER POSITION (See page AT-353)
 TF–40 VF4BM TRANSFER – TRANSFER ASSEMBLY

26. CHECK FOR EXHAUST GAS LEAKAGE

27. WARM UP
28. DRIVE TEST

TF
 PP–50 PREPARATION – VF4BM TRANSFER

VF4BM TRANSFER
PREPARATION

SST
09223-15020 Oil Seal & Bearing Replacer

PP 09223-46011 Crankshaft Front Oil Seal

Replacer

09308-00010 Oil Seal Puller

09316-60011 Transmission & Transfer Bearing

Replacer

(09316-00011) Replacer Pipe

(09316-00031) Replacer B

(09316-00071) Replacer F

09330-00021 Companion Flange Holding Tool

09515-30010 Rear Wheel Bearing Replacer

09554-30011 Differential Oil Seal Replacer

09555-55010 Differential Drive Pinion

Bearing Replacer
 PREPARATION – VF4BM TRANSFER PP–51

09612-65014 Steering Worm Bearing Puller

(09612-01030) Claw C

PP
(09612-01050) Hanger Pin with Nut

09631-32020 Seal Ring Tool

09950-40011 Puller B Set

(09951-04020) Hanger 200

(09952-04010) Slide Arm

(09953-04030) Center Bolt 200

(09954-04010) Arm 25

(09955-04051) Claw No.5

(09957-04010) Attachment

(09958-04011) Holder
 PP–52 PREPARATION – VF4BM TRANSFER

09950-60010 Replacer Set

(09951-00320) Replacer 32

PP
(09951-00570) Replacer 57

(09951-00590) Replacer 59

09950-70010 Handle Set

(09951-07100) Handle 100

 SS–46 SERVICE SPECIFICATIONS – VF4BM TRANSFER

VF4BM TRANSFER
SERVICE DATA
Output shaft rear
STD 0.15 to 0.24 mm (0.0059 to 0.0094 in.)
Drive sprocket thrust clearance
Max. 0.24 mm (0.0094 in.)
STD 0.01 to 0.06 mm (0.0004 to 0.0024 in.)
Drive sprocket radial clearance
Max. 0.06 mm (0.0024 in.)

SS Gear shift fork No. 2 claw thickness

High and low clutch sleeve groove distance
10 mm (0.3937 in.)
10.5 mm (0.4134 in.)
STD 0.26 to 0.84 mm (0.0102 to 0.0331 in.)
Gear shift fork No. 2 to high and low clutch sleeve clearance
Max. 0.84 mm (0.0331 in.)
CTR differential lock fork claw thickness 10 mm (0.3937 in.)
Front drive clutch sleeve groove distance 10.5 mm (0.4134 in.)
STD 0.26 to 0.84 mm (0.0102 to 0.0331 in.)
CTR differential lock fork to front drive clutch sleeve clearance
Max. 0.84 mm (0.0331 in.)
Rear output shaft journal outer diameter
STD 27.98 to 27.99 mm (1.1016 to 1.1020 in.)
Part A
Min. 27.98 mm (1.1016 in.)
STD 31.98 to 32.00 mm (1.2591 to 1.2598 in.)
Part B
Min. 31.98 mm (1.2591 in.)
STD 34.98 to 35.00 mm (1.3772 to 1.3780 in.)
Part C
Min. 34.98 mm (1.3772 in.)
STD 36.98 to 37.00 mm (1.4559 to 1.4567 in.)
Part D
Min. 36.98 mm (1.4559 in.)

Input shaft
Input shaft journal outer diameter Min. 47.59 mm (1.8736 in.)
Input shaft bushing diameter Max. 48.14 mm (1.8953 in.)
Mark
A 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
B 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
C 2.20 to 2.25 mm (0.0866 to 0.0886 in.)
D 2.25 to 2.30 mm (0.0886 to 0.0906 in.)
E 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
F 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
G 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
H 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
J 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
Input gear stopper snap ring thickness
K 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
L 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
M 2.65 to 2.70 mm (0.1043 to 0.1063 in.)
N 2.70 to 2.75 mm (0.1063 to 0.1083 in.)
P 2.75 to 2.80 mm (0.1083 to 0.1102 in.)
Q 2.80 to 2.85 mm (0.1102 to 0.1122 in.)
R 2.85 to 2.90 mm (0.1122 to 0.1142 in.)
S 2.90 to 2.95 mm (0.1142 to 0.1161 in.)
T 2.95 to 3.00 mm (0.1161 to 0.1181 in.)
U 3.00 to 3.05 mm (0.1181 to 0.1201 in.)
 SERVICE SPECIFICATIONS – VF4BM TRANSFER SS–47

Planetary gear
STD 0.11 to 0.84 mm (0.0043 to 0.0331 in.)
Pinion gear thrust clearance
Max. 0.84 mm (0.0331 in.)
STD 0.009 to 0.038 mm (0.0004 to 0.0015 in.)
Pinion gear radial clearance
Max. 0.038 mm (0.0015 in.)
Mark
1 1.45 to 1.50 mm (0.0571 to 0.0591 in.)
2 1.50 to 1.55 mm (0.0591 to 0.0610 in.)
Input bearing shaft snap ring thickness
3 1.55 to 1.60 mm (0.0610 to 0.0630 in.)
4 1.60 to 1.65 mm (0.0630 to 0.0650 in.) SS
5 1.65 to 1.70 mm (0.0650 to 0.0669 in.)
Low planetary gear bearing press in depth 7.7 to 8.3 mm (0.303 to 0.327 in.)
VF4BM TRANSFER – TRANSFER SYSTEM TF–1

TRANSFER SYSTEM
PRECAUTION
• Before disassembly, clean the transfer assembly and
remove any deposited sand and mud to prevent it from
entering the transfer during disassembly and assembly.
• When removing any light alloy parts such as the transfer
covers, do not pry them off with a tool like a screwdriver,
but tap them out with a plastic hammer.
• Always organize the removed parts properly and protect TF
them from dust.
• After cleaning and drying the transfer completely before
installation, apply hypoid gear oil to each part. Do not use
alkaline chemicals when cleansing aluminum or rubber
parts or ring gear set bolts. Also, do not use any cleansing
oil (ex. white gasoline) to clean rubber parts such as oil
seals.
• Apply sufficient hypoid gear oil to all sliding surfaces and
rotating parts.
• Do not directly hold any parts in a vise. Be sure to put an
aluminum sheet between them.
• Replace any damaged or deformed snap rings with new
ones.
• If the mating surface of the case is scratched, it could
cause oil leakage. Therefore, handle with care to prevent
such damage.
• Using a razor blade and gasket scraper, remove old FIPG
from the seal surface.
• Clean all the components to remove the redundant FIPG
completely.
• Clean the sealing surface with solvent so that no residue
remains on the seal surface.
• Apply a line of FIPG approximately 1.2 mm (0.047 in.)
diameter of bead state along the sealing surface.
• Be sure to assemble parts within 10 minutes of application.
Otherwise, the FIPG must be removed and reapplied.
• Do not pour in oil immediately after installing sealed parts.
Leave it for at least an hour.
• Scratches on the contact surface with an oil seal or gasket
could cause oil leakage. Handle with care to prevent such
damage.
• When press-fitting an oil seal, take care to prevent the oil
seal lip and its periphery from being damaged.
• When servicing or disconnecting the 4WD ECU, be sure to
disconnect all power by removing the 20A 4WD fuse or the
negative battery terminal. Failure to disconnect power for
the 4WD ECU before performing Repair Manual diagnostic
procedures may cause the transfer case actuator to be
activated, resulting in damage to the transfer case
actuator.
 TF–2 VF4BM TRANSFER – TRANSFER SYSTEM

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem.
The numbers indicate the ranked order of probability of each
of the possible causes.
Check each part in order.
Replace the applicable parts as necessary.
TRANSFER SYSTEM
Symptom Suspected area See page
1. Oil (Level low) TF-3
TF Noise 2. Oil (Wrong) TF-3
3. Transfer faulty TF-4
1. Oil (Level too high) TF-3
2. Gasket (Damaged) TF-4
Oil leakage
3. Oil seal (Worn or damaged) TF-4
4. O-ring (Worn or damaged) TF-4
Tight corner braking 1. Center differential or transfer faulty TF-43
1. Four wheel drive control switch TF-45
Shift from 4WD (H4) to 4WD (L4) impossible 2. Wire harness TF-46
3. Four wheel drive control ECU TF-46
1. Four wheel drive control switch TF-45
Shift from 4WD (L4) to 4WD (H4) impossible 2. Wire harness TF-46
3. Four wheel drive control ECU TF-46
 VF4BM TRANSFER – TRANSFER OIL TF–3

0 to 5 mm
TRANSFER OIL
(0 to 0.20 in.)
ADJUSTMENT
1. INSPECT TRANSFER OIL
(a) Remove the filler plug and gasket.
(b) Check that the oil level is within 5 mm (0.20 in.) of
the bottom of the filler plug hole.
NOTICE:
• When replacing the oil, recheck the oil level
C083746E02

after driving. TF
• Excessively large or small quantities of oil
may cause troubles.
(c) When the oil level is too low, check for oil leakage.
(d) Tighten the filler plug with a new gasket.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
2. ADJUST TRANSFER OIL
(a) Remove the filler plug and gasket then supply oil.
NOTICE:
• When supplying oil, pour slowly.
• Pour the oil in several stages allowing several
minutes between each step.
HINT:
The oil level should be within 5 mm (0.20 in.) of the
bottom of the oil filler plug hole.
(b) After leaving it alone for 5 minutes, check the oil
level again.
(c) Tighten the filler plug with a new gasket.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
 TF–4 VF4BM TRANSFER – TRANSFER ASSEMBLY

TRANSFER ASSEMBLY
DRIVE LINE
VF4BM TRANSFER

COMPONENTS

TF
88 (900, 65)

ATF LEVEL GAUGE

PROPELLER SHAFT ASSEMBLY

12 (122, 9)

88 (900, 65)

O-RING

TRANSMISSION OIL FILTER

TUBE SUB-ASSEMBLY

5 (50, 43 in.*lbf) 34 (346, 25) TRANSFER ASSEMBLY

x5
24 (240, 17)

OIL COOLER INLET TUBE NO. 1 AND

OIL COOLER OUTLET TUBE NO. 1
18 (184, 13)

48 (490, 35)
TRANSFER
CASE LOWER
x6 PROTECTOR
24 (240, 17)
x3
FLYWHEEL HOUSING TRANSMISSION
UNDER COVER CONTROL CABLE
71 (720, 53)

AUTOMATIC TRANSMISSION ASSEMBLY

18 (184, 13) 88 (900, 65)

PROPELLER SHAFT
ASSEMBLY FRONT

N*m (kgf*cm, ft.*lbf) : Specified torque 88 (900, 65)

Non-reusable part

C131350E02
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–5

48 (490, 35)

GASKET

EXHAUST PIPE TF
ENGINE MOUNTING
GASKET INSULATOR REAR NO. 1

62 (630, 46) 62 (630, 46)

65 (663, 48)
GASKET

ENGINE UNDER COVER FRONT CROSSMEMBER 72 (734, 53)

SUB-ASSEMBLY NO. 1 SUB-ASSEMBLY NO. 3

72 (734, 53)

33 (336, 24)

ENGINE UNDER COVER

ASSEMBLY REAR 33 (336, 24)

FRONT SUSPENSION MEMBER BRACKET LH

FRONT SUSPENSION MEMBER BRACKET

Non-reusable part

C131351E01
 TF–6 VF4BM TRANSFER – TRANSFER ASSEMBLY

18 (185, 13)

CASE PLUG 18.6 (190, 14)

CASE COVER SUB-ASSEMBLY
TF
COMPRESSION BREATHER OIL
SPRING DEFLECTOR

HEAD PIN
FRONT BEARING
RETAINER SUB-
ASSEMBLY

SNAP RING

LOW PLANETARY
11.5 (119, 8)
RING GEAR
x5

SNAP RING

OIL SEAL
TRANSFER FRONT CASE

OIL SEAL

118 (1,200, 87)

OIL SEAL

OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

Precoated part
C131342E06
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–7

TF
BALL

SPACER

TRANSFER OUTPUT SHAFT

FRONT NEEDLE ROLLER
BEARING

TRANSFER INPUT SHAFT

THRUST BEARING RACE NO. 1

TRANSFER LOW PLANETARY GEAR BEARING

LOW PLANETARY GEAR ASSEMBLY

PLANETARY CARR WASHER

INPUT GEAR STOPPER

7.5 (80, 66 in.*lbf)

SNAP RING 7.5 (80, 66 in.*lbf)

MAGNET

TRANSFER OIL SEPARATOR

O-RING SUB-ASSEMBLY
TRANSFER OIL
PUMP GEAR

TRANSFER OIL PUMP BODY SUB-ASSEMBLY 7.5 (80, 66 in.*lbf)

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
C131343E03
 TF–8 VF4BM TRANSFER – TRANSFER ASSEMBLY

20 (200, 15)

CTR DIFFERENTIAL LOCK

FORK SUB-ASSEMBLY
SNAP RING 20 (200, 15)
TF
24 (245, 18)
TRANSFER SHIFT
ACTUATOR
GEAR SHIFT FORK NO. 2
ASSEMBLY
SNAP RING
CLAMP

x12
24 (245, 18)

28 (285, 21)

GASKET
REAR OUTPUT SHAFT
SUB-ASSEMBLY
37 (380, 27)
NO. 1 PLUG
(FILLER PLUG)

37 (380, 27)
NO. 1 PLUG
(DRAIN PLUG)
GASKET

TRANSFER CASE REAR

FRONT DRIVE
CLUTCH SLEEVE FRONT DRIVE CHAIN
HIGH AND LOW
CLUTCH SLEEVE
DRIVEN SPROCKET SUB-ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

C131353E01
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–9

TF

12 (120, 9)
118 (1,200, 87)

x5

OIL SEAL

OUTPUT SHAFT COMPANION

FLANGE SUB-ASSEMBLY
OIL SEAL

TRANSFER EXTENSION HOUSING SUB-ASSEMBLY REAR

COLLAR

OUTPUT WASHER

SNAP RING

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

Precoated part
C131568E01
 TF–10 VF4BM TRANSFER – TRANSFER ASSEMBLY

INPUT SHAFT:

TRANSFER NO. 1 INPUT

SHAFT SEAL RING

TF

TRANSFER INPUT SHAFT

Non-reusable part
C131346E03

DRIVEN SPROCKET SUB-ASSEMBLY:

DRIVEN SPROCKET

TRANSFER INPUT GEAR

RADIAL BALL BEARING
TRANSFER DRIVEN
SPROCKET BEARING
Non-reusable part
C131347E03
 VF4BM TRANSFER – TRANSFER ASSEMBLY TF–11

LOW PLANETARY GEAR SUB-ASSEMBLY:

SNAP RING

LOW PLANETARY GEAR TF

TRANSFER LOW
PLANETARY GEAR
LOW PLANETARY SPLINE PIECE
GEAR BEARING

TRANSFER INPUT SHAFT BEARING

SNAP RING

Non-reusable part
C131348E04
 TF–12 VF4BM TRANSFER – TRANSFER ASSEMBLY

REAR OUTPUT SHAFT SUB-ASSEMBLY:

TRANSFER OUTPUT SHAFT

REAR RADIAL BALL BEARING
NO. 1 TRANSFER OUTPUT SHAFT SPACER

DRIVE SPROCKET SUB-ASSEMBLY

TF DRIVE SPROCKET BEARING

OUTPUT SHAFT
PLATE WASHER

TRANSFER OUTPUT
SHAFT REAR

OUTPUT SHAFT
PLATE WASHER

TRANSFER OUTPUT
SHAFT FRONT NEEDLE
ROLLER BEARING

BALL
CLUTCH HUB

SNAP RING
CENTER DIFFERENTIAL CASE

NO. 2 TRANSFER OUTPUT SHAFT

SPACER
Non-reusable part

C131357E01
 VF4BM TRANSFER – TRANSFER CASE OIL SEAL TF–39

TRANSFER CASE OIL SEAL

DRIVE LINE
VF4BM TRANSFER

COMPONENTS

18 (185, 13)

TF
18.6 (190, 14)
CASE PLUG
CASE COVER
SUB-ASSEMBLY

COMPRESSION SPRING LOW PLANETARY RING GEAR

BREATHER OIL
HEAD PIN DEFLECTOR

SNAP RING

* 11.5 (117, 8)

x5

SNAP RING

OIL SEAL FRONT BEARING RETAINER TRANSFER FRONT CASE

SUB-ASSEMBLY

OIL SEAL

TRANSFER CASE OIL SEAL

118 (1,200, 87)

OUTPUT SHAFT COMPANION

FLANGE SUB-ASSEMBLY
N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

* Precoated part
C131342E03
 TF–40 VF4BM TRANSFER – TRANSFER CASE OIL SEAL

REMOVAL
1. DRAIN TRANSFER OIL
2. REMOVE TRANSFER CASE LOWER PROTECTOR
(See page TF-13)
3. REMOVE AUTOMATIC TRANSMISSION WITH
TRANSFER
HINT:
(See page AT-347)
TF 4. REMOVE OUTPUT SHAFT COMPANION FLANGE
SUB-ASSEMBLY (See page TF-14)
5. REMOVE TRANSFER CASE OIL SEAL
SST (a) Using SST, remove the oil seal.
SST 09308-00010
NOTICE:
Do not damage the oil-seal-fitted surface of the
case.

F043485E02

INSTALLATION
1. INSTALL TRANSFER CASE OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.
(b) Using SST and a hammer, tap in the oil seal until its
surface is flush with the case upper surface.
SST 09316-60011 (09316-00011)
2. INSTALL OUTPUT SHAFT COMPANION FLANGE
SUB-ASSEMBLY (See page TF-36)
SST
F043487E02
3. INSTALL AUTOMATIC TRANSMISSION WITH
TRANSFER
HINT:
(See page AT-350)
4. INSTALL TRANSFER CASE LOWER PROTECTOR
(See page TF-37)
5. ADD TRANSFER OIL
6. ADD AUTOMATIC TRANSMISSION FLUID
7. INSPECT AUTOMATIC TRANSMISSION FLUID
8. WARMING UP
9. DRIVE TEST
 VF4BM TRANSFER – EXTENSION HOUSING OIL SEAL TF–41

EXTENSION HOUSING OIL SEAL

DRIVE LINE
VF4BM TRANSFER

COMPONENTS

OUTPUT SHAFT COMPANION

FLANGE SUB-ASSEMBLY

TF

TRANSFER EXTENSION
HOUSING TYPE T OIL SEAL

C139738E02
 TF–42 VF4BM TRANSFER – EXTENSION HOUSING OIL SEAL

REMOVAL
1. DRAIN TRANSFER OIL
2. REMOVE TRANSFER CASE LOWER PROTECTOR
(See page TF-13)
3. REMOVE AUTOMATIC TRANSMISSION WITH
TRANSFER
HINT:
(See page AT-347)
TF 4. REMOVE OUTPUT SHAFT COMPANION FLANGE
SUB-ASSEMBLY (See page TF-14)
5. REMOVE TRANSFER EXTENSION HOUSING TYPE T
SST OIL SEAL
(a) Using SST, remove the oil seal.
SST 09308-00010
NOTICE:
Do not damage the oil-seal-fitted surface of the
extension housing sub-assembly rear.

F043484E02

INSTALLATION
1. INSTALL TRANSFER EXTENSION HOUSING TYPE T
SST OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.
(b) Using SST and a hammer, tap in the oil seal until its
surface is flush with the housing upper surface.
SST 09223-46011, 09631-32020
2. INSTALL OUTPUT SHAFT COMPANION FLANGE
F043486E02 SUB-ASSEMBLY (See page TF-36)
3. INSTALL AUTOMATIC TRANSMISSION WITH
TRANSFER
HINT:
(See page AT-350)
4. INSTALL TRANSFER CASE LOWER PROTECTOR
(See page TF-37)
5. ADD TRANSFER OIL
6. ADD AUTOMATIC TRANSMISSION FLUID
7. INSPECT AUTOMATIC TRANSMISSION FLUID
8. WARMING UP
9. DRIVE TEST
 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM TF–43

CENTER DIFFERENTIAL LOCK SYSTEM

DRIVE LINE
VF4BM TRANSFER

PARTS LOCATION

TF

DIFFERENTIAL
LOCK SWITCH
FOUR WHEEL DRIVE
CONTROL ECU

FOUR WHEEL DRIVE

CONTROL SWITCH

TRANSFER SHIFT
ACTUATOR ASSEMBLY

C131358E02
 TF–44 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM

INSPECTION
NOTICE:
• Switch the four wheel drive control switch under the
condition that A/T shift lever is in "N" position and the
vehicle speed is 5 km/h or less.
• Do not operate the four wheel drive control switch
and the differential lock switch at the same time.
1. INSPECT H4 (DIFFERENTIAL LOCK "FREE") TO H4
(DIFFERENTIAL LOCK "LOCK") SHIFT
TF (a) Start the engine, and the differential lock switch is in
"OFF" position.
(b) Turn the four wheel drive control switch to "H4"
position while pressing it.
(c) Check that the center diff. lock indicator light comes
on after pressing the differential lock switch for 2
seconds. Check that the center diff. lock indicator
F044042 light goes off after pressing the differential lock
switch for 2 seconds.
2. INSPECT L4 (DIFFERENTIAL LOCK "FREE" TO H4
(DIFFERENTIAL LOCK "LOCK") SHIFT
(a) Start the engine, and differential lock switch is in
"OFF" position.
(b) Turn the four wheel drive control switch to "L4"
position while pressing it.
(c) Check that the 4LO indicator light comes on after it
is blinking.
(d) Check that the center diff. lock indicator light comes
on after pressing the differential lock switch for 2
seconds. Check that the center diff. lock indicator
light goes off after pressing the differential lock
switch for 2seconds.

F044043

3. INSPECT H4 (DIFFERENTIAL LOCK "FREE") TO L4

(DIFFERENTIAL LOCK "LOCK") SHIFT
(a) Start the engine, and differential lock switch is in
"OFF" position.
(b) Turn the four wheel drive control switch from the
"H4" position to the "L4" position while pressing it.
(c) Check that the 4LO indicator light comes on after it
is blinking.
(d) Turn the four wheel drive control switch from the
F044044 "L4" position to the "H4" position while pressing it.
(e) Check that the 4LO indicator light goes off after it is
blinking.
 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM TF–45

4. INSPECT H4 (DIFFERENTIAL LOCK "LOCK") TO L4

(DIFFERENTIAL LOCK "LOCK") SHIFT
(a) Start the engine, and differential lock switch is in
"OFF" position.
(b) Check that the center diff. lock indicator light comes
on after pressing the differential lock switch for 2
seconds.
(c) Turn the four wheel drive control switch from the
"H4" position to the "L4" position while pressing it.
(d) Check that the 4LO indicator light comes on after it
is blinking. TF
(e) Turn the four wheel drive control switch from the
"L4" position to the "H4" position while pressing it.
(f) Check that the 4LO indicator light goes off after it is
blinking.
F044045

5. INSPECT DIFFERENTIAL LOCK SWITCH

CONTINUITY
(a) Remove the instrument panel finish lower panel
sub- assembly.
(b) Remove the differential lock switch from the
instrument panel finish lower sub-assembly.
(c) Inspect the continuity between the each terminal.
Switch position Tester connection Specified condition
OFF ON OFF +B (3) - GND (4) No continuity
Hold ON +B (3) - GND (4) Continuity
Illumination ILL+ (1) - ILL- (2) Continuity
GND ILL-
If continuity is not as specified, replace the
differential lock switch or bulb.

+B ILL+

F044040E02

6. INSPECT FOUR WHEEL DRIVE CONTROL SWITCH

(a) (a) Remove the center instrument cluster finish
panel sub- assembly.
(b) Remove the four wheel drive control switch from the
center instrument cluster finish panel sub-assembly.
(c) Inspect the continuity between the each terminals.
Switch position Tester connection Specified condition
H4 LO (2) - GND (4) No continuity
GND ILL- LO ILL+ L4 LO (2) - GND (4) Continuity
F044039E04
Illumination ILL+ (1) - ILL- (3) Continuity

If continuity is not as specified, replace the four

wheel drive control switch or bulb.
 TF–46 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM

7. INSPECT ACTUATOR
NOTICE:
Inspection for the actuator must be done with the
actuator installed on the transfer assembly.
(a) Turn the ignition switch to ON.
(b) Check the operating sound produced by four wheel
drive control switch operation and the differential
lock switch operation.
If the operating sound cannot be heard, check the
four wheel control ECU and the wire harness in the
TF next step. When the wire harness and four wheel
drive control ECU is normal, replace the actuator.
8. INSPECT WIRE HARNESS
(a) Disconnect the cable from the negative battery
Four Wheel Drive Control ECU Connector
terminal or remove the 20A 4WD fuse.
F10
CAUTION:
Failure to disconnect power for the 4WD ECU
may cause the transfer case actuator to be
activated, resulting in damage to the transfer
case actuator.
(b) Disconnect the actuator connector and four wheel
drive control ECU connector.
(c) Check continuity on the wire harness between four
Transfer Shift Actuator Connector wheel drive control ECU and the actuator.
Tester connection Specified condition
T3
TM1 (F10-2) - TM1 (T3-2) Continuity
TM2 (F10-5) - TM2 (T3-1) Continuity
TL2 (F10-24) - TL2 (T3-4) Continuity
TL3 (F10-23) - TL3 (T3-5) Continuity
HM2 (F10-4) - HM2 (T3-7) Continuity
HM1 (F10-1) - HM1 (T3-8) Continuity

F044038E02
P1 (F10-22) - CDL (T3-9) Continuity
HL2 (F10-26) - HL2 (T3-11) Continuity
HL1 (F10-17) - HL1 (T3-12) Continuity

If continuity is not as specified, repair or replace the

wire harness.
9. INSPECT FOUR WHEEL DRIVE CONTROL ECU
(a) Connect the wire harness side connector to the four
wheel drive control ECU.
(b) Connect the cable to the negative battery terminal
or install the 20A 4WD fuse.
 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM TF–47

(c) Inspect the wire harness side connector from the

back side, as shown below.

F9 F10

TF
C134067E02

STANDARD VALUE OF ECU TERMINAL

Terminals (Symbols) Condition STD Voltage (V)

F9-9 (SPD) - F9-1 (GND) During driving Pulse generation
• Ignition switch ON
F9-22 (N) - F9-1 (GND) • Transmission shift lever other position → 10 to 14 → 2 or less
Transmission shift lever N position
• Ignition switch ON
• Differential lock switch is in "OFF" position
F9-16 (DL) - F9-1 (GND) 10 to 14 → 2 or less
→ Keep pressing the differential lock
switch approx. 2 seconds to turn it ON
• Ignition switch ON
• Differential lock switch is in "OFF" position
F10-23 (TL3) - F9-1 (GND) 2 or less → 10 to 14
→ Keep pressing the differential lock
switch approx. 2 seconds to turn it ON
F9-6 (IG) - F9-1 (GND) Ignition switch ON 10 to 14
• Ignition switch ON
• Differential lock switch is in "OFF" position
10 to 14 (for about 5 seconds) then less than
F10-2 (TM1) - F10- 5 (TM2) • Ignition switch ON 0.5
• Keep pressing the differential lock switch
approx. 2 seconds to turn it ON
• Ignition switch ON
• Four wheel drive control switch "H4"
F9-15 (LO) - F9-1 (GND) 10 to 14 → 2 or less
position → Four wheel drive control switch
"L4" position
• Ignition switch ON
• Differential lock switch is in "OFF" position
F9-20 (IND2) - F9-1 (GND) 10 to 14 → 1.5 to 3.5
→ Keep pressing the differential lock
switch approx. 2 seconds to turn it ON
• Ignition switch ON
• Four wheel drive control switch "H4"
F9-11 (IND3) - F9-1 (GND) 10 to 14 → 1.5 to 3.5
position → Four wheel drive control switch
"L4" position
• Ignition switch ON
• Differential lock switch is in "OFF" position
F10-24 (TL2) - F9-1 (GND) 10 to 14 → 2 or less
→ Keep pressing the differential lock
switch approx. 2 seconds to turn it ON
F9-1 (GND) - Body ground Ignition switch OFF Continuity
• Ignition switch ON
• Four wheel drive control switch "H4"
F9-24 (L4) - F9-1 (GND) 10 to 14 → 2 or less
position → Four wheel drive control switch
"L4" position
• Ignition switch ON
• Four wheel drive control switch "H4"
F10-1 (HM1) - F9-1 (GND) 10 to 14 → 2 or less
position → Four wheel drive control switch
"L4" position
 TF–48 VF4BM TRANSFER – CENTER DIFFERENTIAL LOCK SYSTEM

Terminals (Symbols) Condition STD Voltage (V)

• Ignition switch ON
• Four wheel drive control switch "H4"
F10-4 (HM2) - F9-1 (GND) 14 2 or less → 10 to 14
position → Four wheel drive control switch
"L4" position
• Ignition switch ON
• Four wheel drive control switch "H4"
F10-17 (HL1) - F9-1 (GND) 10 to 14 → 2 or less
position → Four wheel drive control switch
"L4" position
• Ignition switch ON
• Four wheel drive control switch "H4"
TF F10-26 (HL2) - F9-1 (GND)
position → Four wheel drive control switch
"L4" position
2 or less → 10 to 14