Repair Procedure - Steps 28 Thru 52

28. Install the transfer shift actuator assembly.

A. Install the actuator assembly with the 3 bolts.

Torque: 20 N.m
(204 kgf.cm, 15 ft.lbf)

B. Using a screwdriver and hammer drive in the 2 snap rings.





29. Install the rear output shaft sub-assembly, front drive chain, and driven sprocket sub-assembly.

A. Install the rear output shaft sub-assembly and driven sprocket to the front drive chain.





B. Install the rear output shaft sub-assembly, front drive chain, and driven sprocket sub-assembly to the case rear.

HINT:
Check that the rear output shaft sub-assembly and driven sprocket sub-assembly turn lightly. If necessary, heat the rear case to about 122 - 176°F (50 - 80°C).





C. Using a snap ring expander, install the snap ring.





30. Install the center differential lock fork sub-assembly w/front drive clutch sleeve.

A. Install the center 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.

NOTE:
Make sure to install the fork and clutch sleeve in the correct direction.





31. Install the transfer gear shift fork No. 2 w/transfer high and low clutch sleeve.

A. Install the gear shift fork No. 2 and high and low shift fork shaft and high and low clutch sleeve.

NOTE:
Make sure to install the fork in the correct direction.

B. Apply sealant to the plug No. 1 threads.

Sealant: P/N 08833-00080, Toyota Genuine Adhesive 1344, Three Bond 1344, Loctite 242, or equivalent

C. Install the spring and ball to the hole.

D. Install the plug No. 1 to the hole.

Torque: 18.6 N.m (190 kgf.cm, 14 ft.lbf)

E. Using a pin punch and hammer, Install the slotted pin.

32. Install the transfer output shaft spacer.





33. Install the transfer output shaft front needle roller bearing.





34. Install the transfer case rear.

A. Apply FIPG sealant to the case rear, as shown.

^ FIPG sealant:
P/N 08826-00090,
Three Bond 1281,
or equivalent





B. Install the 2 clamps and case rear with the 12 bolts.

Torque: 28 N.m
(285 kgf.cm, 21 ft.lbf)





35. Install the collar and 2 transfer output washers.





36. Install the transfer extension housing type T oil seal.

A. Using the SSTs and a hammer, drive in a NEW oil seal until its surface is flush with the housing upper surface.

^ SST P/N 00002-62091-02
(09223-46011), 09631-32020

B. Coat the lip of the oil seal with MP grease.





37. Install the extension housing assembly.

A. Apply FIPG sealant to the extension housing assembly rear, as shown.

^ FIPG sealant:
P/N 08826-00090,
Three Bond 1281,
or equivalent

B. Apply sealant to the bolt threads.

^ Sealant: P/N 08833-00080,
Toyota Genuine Adhesive 1344,
Three Bond 1344,
Loctite 242, or equivalent





C. Install the extension housing assembly with the 5 bolts.

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

38. Install the front transfer output shaft companion flange oil seal.

A. Using the SSTs and a hammer, drive in a NEW oil seal.

^ SST P/N 09950-60010-02
(09951-00320-01),
09950-70010-02
(09951-07100-01)

B. Coat the lip of the oil seal with MP grease.

39. Install the rear transfer output shaft companion flange oil seal.

A. Using the SSTs and a hammer, drive in a NEW oil seal.

^ SST P/N 09950-60010-02
(09951-00320-01),
09950-70010-02
(09951-07100-01)

B. Coat the lip of the oil seal with MP grease.





40. Install the front output shaft companion flange sub-assembly.

A. Install the companion flange sub-assembly to the drive sprocket sub-assembly.

B. Using the SST to hold the companion flange, install a NEW companion flange lock nut.

^ SST P/N 09330-00021
Torque: 118 N.m
(1,203 kgf.cm, 87 ft.lbf)

C. Using a chisel and hammer, stake the companion flange lock nut.

41. Install the rear output shaft companion flange sub-assembly.

Using the SST, install the rear companion flange sub-assembly in the same way as the front companion flange sub-assembly.

^ SST P/N 09330-00021
Torque: 118 N.m
(1,203 kgf.cm, 87 ft.lbf)





42. Install the breather oil deflector.

43. Install the transfer case cover sub-assembly with the 4 bolts.

Torque: 18 N.m
(184 kgf.cm, 13 ft.lbf)

44. Install the transfer cover type T oil seal.

A. Using the SSTs and a hammer, drive in a NEW oil seal until its surface is flush with the retainer upper surface.

B. Coat the lip of the oil seal with MP grease.

^ SST P/N 09950-60010-02
(09951-00590-01),
09950-70010-02
(09951-07100-01)





45. Install the transfer RH bearing retainer sub-assembly.

A. Apply FIPG sealant to the bearing retainer sub-assembly, as shown.

^ FIPG sealant:
P/N 08826-00090, Three Bond 1281, or equivalent

B. Apply sealant to the bolt thread.

Sealant: P/N 08833-00080,
Toyota Genuine Adhesive 1344, Three Bond 1344,
Loctite 242, or equivalent

C. Install the bearing retainer sub-assembly with the 5 bolts.

Torque:
11.5 N.m (117 kgf.cm, 8 ft.lbf)





46. Install the transfer gear shift head No. 2.

Using a pin punch and hammer, install the slotted pin to the gear shift head No. 2.





47. Install the switches. Install NEW gaskets, the indicator switches, and the case No.1 plug.

Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)





48. Install hoses.

NOTE:

^ Place the hose between the transfer rear case and the actuator motor.

^ Adjust the clamp position to prevent excessive bending, pulling, or pushing on the hose.

49. Install the transfer assembly.

A. Install the transfer to the automatic transmission.

B. Install the 2 clamps and 8 bolts.

Torque: 24 N.m (245 kgf.cm, 17 ft.lbf)

50. Install the automatic transmission assembly.

Refer to TIS, 2003 or 2004 model year GX 470 Repair Manual: Automatic Transmission / Trans: Automatic Transmission Assy: Replacement

51. Install the transfer case lower protector with the 4 bolts.

Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)

52. Add transfer oil.

Refer to TIS, 2003 or 2004 model year GX 470 Repair Manual: Transfer: Transfer Oil: Adjustment