Toyota Tundra. Manual — part 2927

6. REMOVE TRANSFER CASE FRONT OIL SEAL

a. Using a screwdriver and hammer, tap out the oil seal from the front case.

7. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

a. Using a chisel and hammer, loosen the staked part of the lock nut.

Fig. 27: Loosening Staked Part Of Lock Nut
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Using SST to hold the companion flange, remove the lock nut.

SST 09330-00021

Fig. 28: Removing Lock Nut Using SST
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Using SST, remove the companion flange.

SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-
04010, 09958-04011)

NOTE:

Be careful not to damage the front case contact surfaces.

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra

Fig. 29: Removing Companion Flange Using SST
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

8. REMOVE TRANSFER CASE REAR OIL SEAL

a. Using a screwdriver and hammer, tap out the oil seal from the rear case.

9. REMOVE NO. 1 TRANSFER CASE PLUG

a. Remove the case plug, compression spring and pin.

Fig. 30: Identifying Case Plug, Compression Spring And Pin
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

10. REMOVE TRANSFER CASE PLUG

a. Using a 10 mm hexagon wrench, remove the case plug.

NOTE:

Be careful not to damage the rear case contact surfaces.

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra

Fig. 31: Identifying Case Plug
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

11. REMOVE REAR TRANSFER CASE

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.

Fig. 32: Identifying Rear Transfer Case Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

12. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK

a. Using 2 screwdrivers and a hammer, tap out the 3 shift fork shaft snap rings.

Fig. 33: Identifying Shift Fork Shaft Snap Rings
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Remove the bolt. Then remove the No. 2 gear shift fork together with the high and low clutch

sleeve from the shift actuator.

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra

Fig. 34: Identifying No. 2 Gear Shift Fork Bolt
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

13. REMOVE NO. 1 TRANSFER GEAR SHIFT FORK

a. Remove the bolt. Then remove the No. 1 gear shift fork together with the front drive clutch sleeve

from the shift actuator.

Fig. 35: Identifying No. 1 Gear Shift Fork Bolt
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

14. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY

a. Remove the 3 bolts. Then remove the shift actuator from the rear case.

Fig. 36: Identifying Shift Actuator Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

15. REMOVE REAR OUTPUT SHAFT

a. Using a snap ring expander, remove the snap ring.

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra