Step Also remove snap ring from input gear bearing. Step Sometimes it is necessary to clearance cover 1 near the input gear as shown. Test fit to see if this is necessary. Step cases only. Install roll pin into shift block. Note position of shift block fingers and shift rod. Assemble as shown above. Step Place new gasket onto cover 2. Step Slide cover 1 onto cover 2.
Carefully tap cover 1 with hammer until cover 1 seats on cover 2. Step Loosely install two bolts on front of cover 1. Do not tighten yet. Step Loosely install two bolts on back of cover 1.
Step Install snap ring onto input gear bearing. Step Install snap ring onto counter shaft bearing. Step Install inner snap ring onto input gear bearing. Step Install inner snap ring onto counter shaft gear bearing. Push shift rod forward. Step Insert interlock pin into either detent spring hole.
Skip this step if installing a twin stick Turn the case on it's side and tap if needed to get pin into place. Step Make sure the interlock pin is all the way into position. Here is can be seen and is not yet in position. Push the pin in until it can no longer be seen. Step On EFI models only, place pin just far enough into shift block so that you can pick up the block.
Step Use the pin to place shift block into transfer case. Slide shift rail into shift block. Step Using a pin punch, drive pin into place.
Step Slide front output gear with bearing into cover 2. Step Install snap ring around the outside of the front output gear bearing. Then place the felt atop the seal, then the metal ring atop the felt, and then lightly press the metal ring until it is flush with the housing.
The metal ring will push against the seal moving it into position. Step Turn over cover 5 and grease inside of rubber seal surface.
Step Place this gasket onto face of cover 2. Step Install cover 5 using 4 bolts. Step Apply grease to ball hole on main shaft and place ball in hole. Step Slide thrust washer onto main shaft and over ball.
Apply grease to face of thrush washer. Step Apply grease to inside and outside of both both front drive cage bearings.
Slide bearings onto main shaft. Step Install front transfer drive gear onto main shaft. Step Apply grease to face of front transfer drive gear. Step Slide clutch hub onto main shaft. Step Install original front drive idler gear. Step Install output shaft rear bearing. Step Slide oil pump drive gear onto main shaft as shown. Step Apply grease to ball hole and place ball into hole. Step Slide speedo drive gear onto main shaft. Step Install oil transfer tubes as shown.
Step Place new gasket onto rear of cover 2. Step Apply grease to cage bearing in rear of cover 3. Step Install cover 3 onto the back of cover 2. Be careful to align oil transfer tubes in the cover. Install 10 bolts into cover 3. Step Install snap ring onto idler bearing. Step Place new gasket onto back of cover 3. Step Remove speedo lock bolts and tab. Using a screwdriver remove the speedo drive gear from cover 4.
Step Remove old seal and install new seal into cover 4. Step Install cover 4 onto the back of cover 3. For accessories purchased after the new vehicle purchase, the coverage is 12 months, regardless of mileage, from the date the accessory was installed on the vehicle, or the remainder of any applicable new vehicle warranty whichever provides greater coverage. Genuine Toyota Accessories Select a vehicle or scroll down to learn more about genuine Toyota accessories. Starting MSRP.
View View Accessories. Hybrid Available. AWD Available. Fuel Cell Electric Vehicle. Plug-in Hybrid. About Toyota Accessories. Add custom wheels to your 4Runner with the TRD in cast bronze wheel. I found a great deal on them here There's many other common tools that are used for the casual gear install but looking at the top of my workbench, these come to mind. The Dremel tool on the left is nice for marking and with the tiny cutting wheel it can be used for cutting old bearings off.
The hammer is almost always in my hands during the gear install. Red Loctite and anti-seize are very important. The soft harborfreight chisel is really handy for seal removal and for starting the pinion races into the carrier pinion bores. And, of course, how would one check the pattern without a good yellow paste?
The yellow paste always comes in the master install kits. It can also be found in a large tube at the Chevy dealership I made my own spanner wrench for properly tightening the adjuster wheels that press against the carrier bearing CBPL. I bought the flat-stock steel 1. I chose to tap and thread the steel flat-stock but it could have also been welded in place. If it doesn't fit just right then a flat file can rub some of the offending threads off until it does.
The other side of my spanner wrench has the extra hard allen heads welded in place. It's nice to have a MIG welder for this :.
I also fine tuned the fit by filing the threads 'til they were squarish. The extra-large wheel adjuster used on the 8" Electric lockers require a custom spanner wrench.
This one took more time to fab up. Not a must-have but a good platform to work on the 3rd is certainly nice
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