Advance Adapters 477021 - Manual (Page 6)

(Step D-1)
(1)
The transfer case must be in 2WD High before
starting the disassembly procedures.
Remove the
nut with a 30mm socket and then remove the flange.
(Step D-2)
(2) Remove the 7 bolts that retain the rear extension housing
with a 14mm metric socket.
HINT:
Keep these bolts in
a separate container. This will reduce the chances of
placing the bolts in the wrong location on reassembly.
(Step D-3)
(3) With the rear extension
housing removed, you
will see the oil pump
and speedometer drive
gears. Slide the gears
off of the rear output
shaft. Take note of the
orientation of the oil
pump and the speed-
ometer gear.
NOTE:
There is a small ball bearing under
the speedometer drive gear. Make sure you store it in a
bag or some other kind of container. These little parts can
walk away.
(Step D-4)
(4) Remove the rear output shaft bearing.
(Step D-6)
(6) Remove the 10 bolts retaining the rear case cover with a
14mm socket. Retain these separately to avoid any confu-
sion during assembly.
Some bolts are different lengths.
Note their location before removal!
(Step D-5)
(5) Remove outer bearing C-clip by reaching inside case and
pushing up on gear, while lightly tapping on the case with
a plastic soft blow mallet.
DISASSEMBLY
TOYOTA TRANSFER CASE
ASSEMBLY & DISASSEMBLY PROCEDURES
These gears are ideal for the avid Toyota Truck rock crawler. These gears are designed for the Toyota Truck gear-driven transfer
case. Depending on the model of your transfer case, some additional modifications may be required. Please refer to the Transfer
Case information section for proper transfer case identification and possible modifications.
The installation of the Toyota gear sets requires you to almost completely disassemble the transfer case. We have provided
illustrative disassembly and assembly instructions to assist you. These instructions are to be used as a guide. The official Toyota
shop manual is strongly recommended for additional information. If your transfer case is in need of a rebuild, now would be the
time to do it.