1 - O-ring, 2 - adapter gasket, 3 - front crankcase cover assembly, 4 - low gear engagement sensor (L4), 5 - front bearing retainer, 6 - high-low gear shift fork assembly, 7 - rear output shaft assembly, 8 - spacer, 9 - speedometer drive pinion, 10 - washer, 11 - thrust washer, 12 - bearing, 13 - power take-off pinion, 14 - spacer, 15 - transfer case pinion, 16 - O-ring, 17 - thrust washer, 18 - intermediate gear assembly, 19 - spacer, 20 - needle bearing, 21 - intermediate gear shaft, 22 - thrust washer, 23 - lock plate, 24 - crankcase, 25 - gasket, 26 - ball, 27 - spring, 28 - plug, 29 - gasket, 30 - side cover, 31 - rear cover, 32 - gasket, 33 - rear bearing holder, 34 - gasket, 35 - speedometer drive driven gear, 36 - ring gasket, 37 - rear output shaft connecting flange, 38 - washer.
1. Disconnect the two sensor connectors on the transfer case.
2. Remove the low gear shift switch (L4).
3. Removing the driven gear of the speedometer drive.
a) Loosen the bolt on the rear bearing holder and remove the driven gear lock plate.
b) Remove the speedometer drive driven gear and remove the O-ring from it.
4. Unscrew the six bolts and remove the side cover (for power take-off mechanism).
5. Using a feeler gauge, measure the clearance between the intermediate gear assembly and the thrust washer.
Permissible clearance - 0.275 - 0.625 mm
6. Remove the six bolts, then remove the rear crankcase cover and gasket.
7. Removing the gearbox output shaft lock nut.
a) Using a hammer and chisel, loosen the countersunk portion of the lock nut.
b) Move the outer high-low gear shift lever on the crankcase to the "H2" or "L4" position.
c) Holding the rear output shaft coupling flange with a special tool, loosen the lock nut and remove the washer.
8. Removing the rear output shaft connecting flange.
a) Using a hammer and chisel, loosen the countersunk portion of the lock nut.
b) Holding the flange with a special tool, unscrew the lock nut, then remove the washer and the connecting flange.
9. Remove the six bolts and the rear bearing retainer together with the gasket.
10. Remove the washer, speedometer drive pinion and spacer from the rear output shaft.
11. Loosen the bolt and remove the intermediate gear shaft lock plate.
12. Unscrew the plug, then use the magnetic rod to remove the spring and ball.
13. Removing the transfer case housing.
a) Unscrew the fourteen bolts.
b) Using a plastic hammer, separate the crankcase from the front cover.
c) Remove the crankcase gasket.
d) Remove the thrust washer from the intermediate gear shaft.
14. Remove the rear output shaft assembly with the high-low shift fork assembly.
15. Removing the drive gear of the power take-off mechanism.
a) Using a special tool, remove the bearing from the gearbox output shaft.
b) Remove the PTO drive gear, then remove the spacer.
(The original can be read on the website: ToyotaMAN.ru)
16. Using a special tool, remove the transfer case drive gear from the gearbox output shaft.
17. Removing the intermediate gear assembly.
a) Remove the O-ring from the intermediate gear shaft.
b) Remove the intermediate gear assembly with two bearings and a spacer.
c) Remove the thrust washer from the intermediate gear shaft.
d) Remove the intermediate gear shaft.
d) Remove the O-ring from the intermediate gear shaft.
18. Remove the rear output shaft front bearing retainer.
19. Remove the four bolts and, using a plastic hammer, pry the front crankcase cover away from the transfer case adapter, then remove the gasket.
20. Remove the O-ring from the gearbox output shaft.
