| Last Modified: 11-29-2007 | 1.6 A | |
| Service Category: Drivetrain | Section: Transfer/4wd/Awd | |
| Model Year: 2008 | Model: Sequoia | Doc ID: RM000002HO8009X |
| Title: JF3A TRANSFER / 4WD / AWD: TRANSFER ASSEMBLY: DISASSEMBLY (2008 Sequoia) | ||
DISASSEMBLY
1. REMOVE HEAT INSULATOR BRACKET
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(a) Remove the heat insulator bracket. |
2. REMOVE TRANSFER CASE PLUG
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(a) Using a 10 mm hexagon wrench, remove the case plug, compression spring, ball and relief valve seat. |
3. REMOVE TRANSFER OIL PUMP PLATE
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(a) Remove the 4 bolts and oil pump plate. NOTICE:
Do not drop the oil pump drive rotor and oil pump driven rotor. |
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(b) Remove the oil seal ring from the input shaft. |
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(c) Remove the drive rotors. |
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(d) Remove the O-ring from the transfer oil pump plate. |
4. REMOVE TRANSFER CASE STRAIGHT PIN
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(a) Remove the 2 straight pins. NOTICE:
Do not drop the straight pins. |
5. REMOVE TRANSFER OIL PUMP PLATE OIL SEAL
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(a) Using a screwdriver and hammer, tap out the oil seal from the oil pump plate. NOTICE:
Be careful not to damage the oil seal and oil pump plate contact surfaces. |
6. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
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(a) Using SST and hammer, loosen the staked part of the lock nut. SST: 09930-00010 |
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(b) Using SST to hold the companion flange. SST: 09330-00021 |
(c) Using a socket wrench (32mm), remove the lock nut.
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(d) Remove the O-ring. |
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(e) Remove the front output shaft companion flange sub-assembly. |
7. REMOVE TRANSFER CASE FRONT OIL SEAL
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(a) Using SST, remove the oil seal from the front case. NOTICE:
Be careful not to damage the front case contact surfaces. |
8. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
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(a) Using SST and hammer, loosen the staked part of the lock nut. SST: 09930-00010 |
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(b) Using SST to hold the companion flange. SST: 09330-00021 |
(c) Using a socket wrench (32mm), remove the lock nut.
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(d) Remove the O-ring. |
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(e) Remove the rear output shaft companion flange sub-assembly. |
9. REMOVE TRANSFER CASE REAR OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal from the rear case.
NOTICE:
Be careful not to damage the rear case contact surfaces.
Remove the 2 output washers.
10. REMOVE NO. 1 TRANSFER CASE PLUG
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(a) Remove the No. 1 transfer case plug, compression spring and pin. |
11. REMOVE TRANSFER CASE PLUG
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(a) Using a 6 mm hexagon wrench, remove the case plug. |
12. REMOVE REAR TRANSFER CASE
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(a) Remove the 14 bolts. |
(b) Remove the rear case.
HINT:
If necessary, tap the rear case with a plastic-faced hammer to remove it.
13. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
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(a) Remove the transfer output shaft front needle roller bearing from the output shaft. |
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(b) Remove the output shaft spacer from the output shaft. |
14. REMOVE NO. 1 SYNCHRONIZER RING
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(a) Remove the No. 1 synchronizer ring from center differential case. |
15. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY
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(a) Using 2 screwdrivers and a hammer, tap out the 3 shift fork shaft snap rings. |
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(b) Remove the 2 bolts. |
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(c) Remove the 3 bolts. Then remove the shift actuator, No.1 gear shift fork and No.2 gear shift fork from the rear case. |
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(d) Remove the o-ring from the transfer shift actuator assembly. |
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(e) Remove the washer from the rear case. |
16. REMOVE TRANSFER HIGH AND LOW CLUTCH SLEEVE
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(a) Remove the transfer high and low clutch sleeve from the output shaft. |
17. REMOVE REAR OUTPUT SHAFT
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(a) Using a snap ring expander, remove the snap ring. |
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(b) Using a plastic-faced hammer, carefully tap the case rear, and remove the output shaft together with the drive chain and driven sprocket. |
(c) Remove the output shaft and driven sprocket from the drive chain.
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(d) Using a snap ring expander, remove the snap ring from the rear transfer case. |
18. REMOVE SIDE GEAR SHAFT HOLDER BEARING
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(a) Using a screwdriver, remove the snap ring. |
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(b) Using SST, remove the bearing. SST: 09308-00010 |
19. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY
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(a) Remove the 3 bolts and oil separator. |
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(b) Remove the O-ring from the oil separator. |
20. REMOVE TRANSFER CASE MAGNET
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(a) Remove the transfer case magnet. |
21. REMOVE INPUT SHAFT ASSEMBLY
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(a) Using a 14 mm hexagon wrench, remove the 2 case plugs from the front case. |
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(b) Remove the snap ring. Then remove the input shaft from the front case. |
22. REMOVE TRANSFER LOW PLANETARY RING GEAR
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(a) Remove the low planetary ring gear from the front case. |
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(b) Using a screw driver, remove the snap ring from the front transfer case. |
23. REMOVE TRANSFER DRIVEN SPROCKET BEARING
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(a) Using a screwdriver, remove the snap ring. |
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(b) Using SST, remove the driven sprocket bearing from the front case. SST: 09950-60020 09951-00680 SST: 09950-70010 09951-07150 |
24. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING
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(a) Remove the oil seal ring from the input shaft. |
25. REMOVE TRANSFER INPUT SHAFT BEARING
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(a) Using a snap ring expander, remove the snap ring. |
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(b) Using SST and a press, pull out the bearing. SST: 09555-55010 SST: 09950-00030 SST: 09950-60010 09951-00480 NOTICE:
Be careful not to drop or damage the low planetary gear. |
26. REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH
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(a) Using SST, remove the bush. SST: 09387-00041 09387-01021 09387-01030 09387-01040 |
27. REMOVE TRANSFER INPUT SHAFT PLUG
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(a) Using SST and a hammer, tap out the input shaft plug. SST: 09950-70010 09951-07150 SST: 09950-60010 09951-00350 |
28. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER
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(a) Using 2 screwdrivers, tap out the snap ring. |
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(b) Remove the output shaft spacer from the output shaft. |
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(c) Remove the seal ring from the output shaft spacer. |
29. REMOVE CENTER DIFFERENTIAL CASE
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(a) Remove the straight pin from the output shaft. |
(b) Remove the center differential case from the output shaft.
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(c) Using a snap ring expander, remove the snap ring. |
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(d) Remove the synchromesh shifting key spring and No. 2 synchromesh shifting keys from the center differential case. |
30. REMOVE FRONT DRIVE CLUTCH SLEEVE
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(a) Remove the front driver clutch sleeve with synchromesh from the output shaft. |
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(b) Remove the 2 transfer clutch hub bearings from shaft. |
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(c) Remove the synchronizer ring set from the drive clutch sleeve. |
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(d) Using a screw driver, remove the 2 shifting key snap rings and 3 shifting keys from the driver clutch sleeve. |
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(e) Remove the transfer clutch hub from the drive clutch sleeve. |
31. REMOVE REAR TRANSFER OUTPUT SHAFT
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(a) Using SST and a press, press out the bearing. SST: 09527-10011 NOTICE:
Be careful not to drop or damage the output shaft. |
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(b) Remove the transfer drive sprocket sub-assembly from the output shaft. |
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(c) Remove the needle roller bearing from the output shaft. |
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