Transfer Case (Service Information): Removal & Installation Lexus IS II facelift 2

REMOVAL [08/2012 - ]

1. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY Refer to «REMOVAL [08/2012 - ]»(ref-606454-S20420207952014032500000)

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1. REMOVE TRANSFER OIL PAN Remove the 9 bolts. Insert the blade of oil pan seal cutter between the transfer oil pan and transfer case. Cut through the sealer and remove the transfer oil pan. NOTE: Do not damage the contact surface of the transfer oil pan. Remove the transfer oil cleaner magnet from the transfer oil pan. NOTE: Clean the inside of the oil pan thoroughly, removing all metal shavings, sludge and any other foreign objects. Remove any metal shavings from the magnet.
2. REMOVE TRANSFER VALVE BODY ASSEMBLY Remove the 4 bolts and the transfer valve body assembly. Disconnect the transfer wire connector from the transfer control solenoid. Remove the bolt and the transfer wire.
3. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR Using SST, remove the transfer extension housing dust deflector. SST: 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09955-04051 09958-04011 NOTE: Apply grease to the threads and tip of the SST center bolt before use.
4. REMOVE TRANSFER CASE Remove the 8 bolts and clamp. Using a plastic hammer, tap the transfer case to remove it.
5. REMOVE TRANSFER REAR OUTPUT SHAFT ASSEMBLY Remove the transfer rear output shaft assembly.
6. REMOVE FLANGE YOKE Using SST and a hammer, release the staked part of the nut. SST: 09930-00010 NOTE: Be sure to use the SST with the tapered surface facing the shaft. Do not grind the tip of the SST with a grinder etc. Completely loosen the staked part of the nut when removing it. Do not damage the threads of the transfer drive sprocket. Using SST, hold the yoke. SST: 09330-00021 SST: 09213-54015 Using a deep socket wrench (30 mm), remove the nut. Remove the flange yoke.
7. REMOVE REAR TRANSFER CHAIN CASE Remove the 10 bolts. Tap the 3 protrusions of the transfer chain case gently with a brass bar and hammer to loosen, and remove it. NOTE: Do not damage the transfer chain case.
8. REMOVE TRANSFER FRONT DRIVE CHAIN Remove the transfer front drive chain, transfer drive sprocket and transfer front driven clutch sleeve. Remove the transfer front drive chain from the transfer drive sprocket and transfer front driven clutch sleeve.
9. REMOVE FRONT TRANSFER CHAIN CASE Remove the 6 bolts and front transfer chain case. HINT: If necessary, tap the transfer chain case front with a plastic hammer to loosen and remove it.
10. REMOVE TRANSFER CASE REAR OIL SEAL Using a screwdriver with its tip taped, pry out the oil seal from the transfer case. Remove the bolt and clamp.
11. REMOVE TRANSFER CASE BEARING Using SST, remove the transfer case bearing from the transfer case. SST: 09308-00010
12. REMOVE TRANSFER BAFFLE VALVE SUB-ASSEMBLY Remove the bolt and transfer baffle valve from the rear transfer chain case.
13. REMOVE TRANSFER CHAIN CASE GOVERNOR APPLY GASKET Remove the screw, O-ring, and 2 gaskets from the front transfer chain case. Remove the 2 gaskets from the rear transfer chain case.
14. REMOVE TRANSFER CASE FRONT OIL SEAL Using a screwdriver with its tip taped, pry out the oil seal from the transfer chain case front.
15. REMOVE CENTER DIFFERENTIAL CARRIER ASSEMBLY Remove the center differential carrier from the transfer rear output shaft and transfer direct clutch drum.
16. REMOVE TRANSFER REAR OUTPUT SHAFT BEARING Remove the transfer rear output shaft bearing from the transfer direct clutch drum.
17. INSPECT CENTER DIFFERENTIAL CARRIER ASSEMBLY See step 1
18. REMOVE CENTER DIFFERENTIAL CLUTCH DISC SET Using a screwdriver with its tip taped, remove the snap ring from the transfer direct clutch drum. Remove the 2 center differential clutch disc flanges and center differential clutch disc set from the transfer direct clutch drum. HINT: Center differential clutch disc flange (No. 1) Center differential clutch disc set (Discs) Center differential clutch disc set (Plates) Center differential clutch disc flange (No. 2)
19. INSPECT CENTER DIFFERENTIAL CLUTCH DISC SET See step 2
20. REMOVE CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER Place SST on the center differential clutch pressure balancer, and compress the return spring with a press. SST: 09350-30020 09350-07040 Using SST, remove the snap ring. SST: 09350-30020 09350-07040 09350-07070 Remove the center differential clutch pressure balancer from the transfer direct clutch drum.
21. REMOVE TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY Remove the transfer direct clutch return spring from the transfer direct clutch drum.
22. INSPECT TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY See step 3
23. REMOVE CENTER DIFFERENTIAL CLUTCH PISTON Install the transfer direct clutch drum to the transfer center support. While pushing down evenly on the center differential clutch piston, apply air (200 kpa, 2.0 kgf*cm 2 , 19 psi) into the oil hole on the transfer chain case rear as shown to remove the center differential clutch piston from the transfer direct clutch drum. Remove the direct clutch drum from the transfer center support.
24. REMOVE TRANSFER DIRECT CLUTCH PISTON O-RING Remove the 2 O-rings from the center differential clutch piston.
25. INSPECT TRANSFER DIRECT CLUTCH DRUM See step 4
26. REMOVE TRANSFER CENTER SUPPORT Remove the 5 bolts and transfer center support. Remove the 2 screws and 2 O-rings from the rear transfer chain case.
27. REMOVE TRANSFER CENTER SUPPORT SEAL RING Remove the 2 transfer center support seal rings from the transfer center support.
28. INSPECT TRANSFER CENTER SUPPORT See step 5
29. REMOVE TRANSFER DRIVEN SPROCKET BEARING Using SST and a press, remove the transfer driven sprocket bearing from the transfer front driven clutch sleeve. SST: 09950-00020 Using SST and a press, remove the transfer driven sprocket bearing from the transfer front driven clutch sleeve. SST: 09950-60010 09951-00530 SST: 09950-70010 09951-07100
30. REMOVE TRANSFER DRIVE SPROCKET BEARING Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket. SST: 09950-00020 SST: 09950-70010 09951-07100 SST: 09950-60010 09951-00480 Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket. SST: 09950-00020 SST: 09950-70010 09951-07100 SST: 09950-60010 09951-00550
31. REMOVE TRANSFER CONTROL SOLENOID Remove the bolt, solenoid lock plate and transfer control solenoid.
32. REMOVE TRANSFER VALVE BODY COVER Remove the 6 bolts. Remove the transfer valve body cover and upper transfer valve body plate from the transfer upper valve body. Remove the solenoid oil strainer from the transfer valve body cover.
33. REMOVE TRANSFER SOLENOID MODULATOR VALVE While pushing on the transfer modulator valve plug, remove the transfer solenoid modulator valve plug seat from the transfer upper valve body. Remove the transfer solenoid modulator valve plug, transfer solenoid modulator valve and low-high shift valve compression spring from the transfer upper valve body.
34. REMOVE CENTER DIFFERENTIAL CLUTCH CONTROL VALVE While pushing on the center differential clutch control valve plug, remove the center differential clutch control valve plug seat from the transfer upper valve body. Remove the center differential clutch control valve plug, center differential clutch control valve, transfer direct clutch modulator valve spring and center differential clutch control valve sleeve from the transfer upper valve body.

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1. INSPECT CENTER DIFFERENTIAL CARRIER ASSEMBLY Using a feeler gauge, measure the center differential carrier pinion gear thrust clearance. Standard clearance 0.2 to 0.5 mm (0.008 to 0.020 in.) If the clearance is greater than the standard clearance, replace the center differential carrier.
2. INSPECT CENTER DIFFERENTIAL CLUTCH DISC SET Check whether the sliding surfaces of the disc and flange are worn or burnt. If necessary, replace them. NOTE: If the lining of the disc is peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.
3. INSPECT TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length 15.2 to 15.8 mm (0.5984 to 0.6220 in.) If the free length is shorter than the standard free length, replace the transfer direct clutch return spring.
4. INSPECT TRANSFER DIRECT CLUTCH DRUM Using a cylinder gauge, measure the inside diameter of the transfer direct clutch drum. Standard inside diameter 65.00 to 65.06 mm (2.559 to 2.564 in.) If the inside diameter is greater than the standard inside diameter, replace the transfer direct clutch drum.
5. INSPECT TRANSFER CENTER SUPPORT Using a cylinder gauge, measure the inside diameter of the transfer center support. Standard inside diameter 49.9 to 50.1 mm (1.965 to 1.972 in.) If the inside diameter is greater than the standard inside diameter, replace the transfer center support.

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1. INSTALL CENTER DIFFERENTIAL CLUTCH CONTROL VALVE Install the center differential clutch control valve sleeve, transfer direct clutch modulator valve spring, center differential clutch control valve and center differential clutch control valve plug to the transfer upper valve body. While pushing on the center differential control valve plug, install the center differential clutch control valve seat on the transfer upper valve body.
2. INSTALL TRANSFER SOLENOID MODULATOR VALVE Install the low-high shift valve compression spring, transfer solenoid modulator valve and transfer solenoid modulator valve plug to the transfer upper valve body. While pushing on the transfer solenoid modulator valve plug, install the transfer solenoid modulator valve plug seat on the transfer upper valve body.
3. INSTALL TRANSFER VALVE BODY COVER Install the solenoid oil strainer to the transfer valve body cover. Install the transfer valve body cover and upper transfer valve body plate to the transfer upper valve body. Install the 6 bolts. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) HINT: Bolt length: Bolt A: 35 mm (1.38 in.) Bolt B: 20 mm (0.79 in.)
4. INSTALL TRANSFER CONTROL SOLENOID Install the transfer control solenoid and solenoid lock plate to the transfer upper valve body with the bolt. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) HINT: Install the solenoid lock plate into the cutout on the transfer control solenoid.
5. INSTALL TRANSFER DRIVE SPROCKET BEARING Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket. SST: 09950-70010 09951-07100 SST: 09950-60010 09951-00640 SST: 09316-20011 Using SST and a press, install a new transfer drive sprocket bearing to the transfer drive sprocket. SST: 09316-60011 09316-00011 NOTE: Install the transfer drive sprocket bearing with the shield facing upward.
6. INSTALL TRANSFER DRIVEN SPROCKET BEARING Using SST and a press, install a new transfer driven sprocket bearing to the transfer front driven clutch sleeve. SST: 09950-70010 09951-07100 SST: 09950-60010 09951-00640 SST: 09316-20011 Using SST and a press, install a new transfer driven sprocket bearing to the transfer front driven clutch sleeve. SST: 09316-60011 09316-00011 09316-00041
7. INSTALL TRANSFER CENTER SUPPORT SEAL RING Coat the 2 seal rings with ATF. Compress the 2 transfer center support seal rings as shown and install them into the grooves on the transfer center support. NOTE: Do not expand the ring ends excessively. If any ring is damaged or deformed, replace it with a new one.
8. INSTALL TRANSFER CENTER SUPPORT Install the transfer center support to the rear transfer chain case with the 5 bolts. Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) Coat 2 new O-rings with ATF. Install the 2 O-rings to the screws. Install the 2 gaskets and 2 screws to the rear transfer chain case. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
9. INSTALL TRANSFER DIRECT CLUTCH PISTON O-RING Coat 2 new O-rings with ATF. Install the 2 O-rings to the transfer direct clutch piston. O-RING SIZE: Installation position Inner diameter mm (in.) Thickness mm (in.) Inner 56.45 to 57.45 (2.222 to 2.262) 2.54 to 2.70 (0.100 to 0.106) Outer 116.20 to 117.80 (4.575 to 4.638) 3.0 to 3.2 (0.118 to 0.126)
10. INSTALL CENTER DIFFERENTIAL CLUTCH PISTON Install the center differential clutch piston to the transfer direct clutch drum. NOTE: Do not damage the O-rings.
11. INSTALL TRANSFER DIRECT CLUTCH RETURN SPRING Install the transfer direct clutch return spring to the transfer direct clutch drum.
12. INSTALL CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER Coat the rubber on the center differential clutch pressure balancer with ATF. Install the center differential clutch pressure balancer to the transfer direct clutch drum. Place SST on the center differential clutch pressure balancer, and compress the return spring with a press. SST: 09350-30020 09350-07040 Using SST, install the snap ring. SST: 09350-30020 09350-07040 09350-07070
13. INSTALL CENTER DIFFERENTIAL CLUTCH DISC SET Install the 2 center differential clutch disc flanges and center differential clutch disc set to the transfer direct clutch drum. HINT: Center differential clutch disc flange (No. 1) Center differential clutch disc set (Discs) Center differential clutch disc set (Plates) Center differential clutch disc flange (No. 2) Install in the following order A - B - C - B - C - B - C - B - C - B - D HINT: A: thickness 2.95 to 3.45 mm (0.116 to 0.136 in.) B: thickness 1.99 to 2.09 mm (0.078 to 0.082 in.) C: thickness 1.95 to 2.05 mm (0.077 to 0.081 in.) D: thickness 2.95 to 3.05 mm (0.116 to 0.120 in.) NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes. Using a screwdriver with its tip taped, install the snap ring to the transfer direct clutch drum. Install the transfer direct clutch drum to the transfer center support. Set the dial indicator perpendicular to the flange. Apply air (200 kpa, 2.0 kgf*cm 2 , 19 psi) into the oil hole as shown. Measure the pack clearance. Standard 0.40 to 0.80 mm (0.016 to 0.031 in.) HINT: Check that the piston moves smoothly. Perform the measurement at 2 or 3 points and take the average. If the clearance is not within the specified range, select another center differential clutch disc flange (No. 1). FLANGE THICKNESS: Thickness mm (in.) Mark 2.95 to 3.05 (0.116 to 0.120) 90 3.15 to 3.25 (0.124 to 0.128) 91 3.35 to 3.45 (0.132 to 0.136) 92 Remove the transfer direct clutch drum from the transfer center support.
14. INSTALL TRANSFER REAR OUTPUT SHAFT BEARING Install the transfer rear output shaft bearing to the transfer direct clutch drum.
15. INSTALL CENTER DIFFERENTIAL CARRIER Install the center differential carrier to the transfer rear output shaft and transfer direct clutch drum.
16. INSTALL TRANSFER CASE FRONT OIL SEAL Using SST and a hammer, install a new oil seal. SST: 09316-60011 09316-00011 09316-00071 Oil seal installation depth 5.6 to 6.2 mm (0.220 to 0.244 in.) Apply MP grease to the oil seal lip.
17. INSTALL TRANSFER CHAIN CASE GOVERNOR APPLY GASKET Coat 2 new gaskets with ATF. Install the 2 gaskets to the rear transfer chain case. Coat a new O-ring and 2 new gaskets with ATF. Install the O-ring to the screw and install it. Install the 2 gaskets and screw to the front transfer chain case. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
18. INSTALL TRANSFER BAFFLE VALVE SUB-ASSEMBLY Install the transfer baffle valve to the rear transfer chain case with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
19. INSTALL TRANSFER CASE BEARING Using SST and a press, install the transfer case bearing to the transfer case. SST: 09950-60020 09951-00890 SST: 09950-70010 09951-07150 Bearing installation depth 94.6 to 94.9 mm (3.724 to 3.736 in.)
20. INSTALL TRANSFER CASE REAR OIL SEAL Using SST and a hammer, install a new oil seal. SST: 09325-40010 Oil seal installation depth 2.3 to 2.7 mm (0.091 to 0.106 in.) Apply MP grease to the oil seal lip. Install the clamp to the transfer case with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
21. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR Using SST and a press, install a new transfer extension housing dust deflector to the transfer case. SST: 09950-70010 09951-07150 SST: 09950-60020 09951-00910
22. INSTALL FRONT TRANSFER CHAIN CASE Remove all residual FIPG material from the contact surfaces using gasoline or alcohol. Apply seal packing to the front transfer chain case as shown. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Temporarily tighten the 6 bolts in several steps, and then tighten them to the specified torque. Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf) HINT: Bolt length: Bolt A: 57 mm (2.24 in.) Bolt B: 74 mm (2.91 in.) Other bolts: 45 mm (1.77 in.)
23. INSTALL TRANSFER FRONT DRIVE CHAIN Install the transfer front drive chain to the transfer drive sprocket and transfer front driven clutch sleeve. Install the transfer front drive chain, transfer drive sprocket and transfer front drive clutch sleeve.
24. INSTALL REAR TRANSFER CHAIN CASE Remove all residual FIPG material from the contacting surfaces using gasoline or alcohol. Apply seal packing to the transfer chain case front as shown. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Temporarily tighten the 10 bolts in several steps, and then tighten to the specified torque. Bolt (A) Torque: 57 N*m (580 kgf*cm, 42 ft.*lbf) Except bolt (A) Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf) HINT: Bolt length: Bolt A: 60 mm (2.36 in.) Bolt B: 50 mm (1.97 in.) Bolt C: 109 mm (4.29 in.) Other bolts: 40 mm (1.57 in.)
25. INSTALL FLANGE YOKE Install the flange yoke. Using SST, hold the yoke. SST: 09213-54015 SST: 09330-00021 Using a deep socket wrench (30 mm), torque a new nut. Torque: 123 N*m (1, 250 kgf*cm, 91 ft.*lbf) Using a chisel and hammer, stake the nut.
26. INSTALL TRANSFER REAR OUTPUT SHAFT ASSEMBLY Install the transfer rear output shaft.
27. INSTALL TRANSFER CASE Remove all residual FIPG material from the contact surfaces using gasoline or alcohol. Apply seal packing to the transfer chain case front as shown. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Temporarily tighten the 8 bolts and clamp in several steps, and then tighten them to the specified torque. Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf) HINT: Bolt length: Bolt A: 88 mm (3.46 in.) Bolt B: 40 mm (1.57 in.)
28. INSTALL TRANSFER VALVE BODY ASSEMBLY Coat the transfer wire O-ring with ATF. Install the transfer wire with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the transfer wire connector to the transfer control solenoid. Install the transfer valve body assembly with the 4 bolts. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
29. INSTALL TRANSFER OIL PAN Install the transfer oil cleaner magnet to the transfer oil pan. Remove all residual FIPG material from the contact surfaces using gasoline or alcohol. Apply seal packing to the transfer chain case front as shown. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Temporarily tighten the 9 bolts in several steps, and then tighten them to the specified torque. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)

INSTALLATION [08/2012 - ]

1. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY Refer to «INSTALLATION [08/2012 - ]»(ref-606454-S14209291822014032500000)

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1. DRAIN AUTOMATIC TRANSMISSION FLUID . Refer to «REMOVAL [08/2012 - ] - Step 3»(ref-606454-S13259800262014032500000)
2. REMOVE REAR NO. 1 FLOOR PANEL BRACE (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 3»(ref-606504-S18686819902014032500000)
3. REMOVE REAR NO. 1 FLOOR PANEL BRACE (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 3»(ref-606484-S00600307052014032500000)
4. REMOVE FRONT CENTER FLOOR BRACE (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 4»(ref-606504-S18686819902014032500000)
5. REMOVE FRONT CENTER FLOOR BRACE (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 4»(ref-606484-S00600307052014032500000)
6. DISCONNECT HEATED OXYGEN SENSOR (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 6»(ref-606504-S18686819902014032500000)
7. DISCONNECT HEATED OXYGEN SENSOR (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 6»(ref-606484-S00600307052014032500000)
8. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 7»(ref-606504-S18686819902014032500000)
9. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 7»(ref-606484-S00600307052014032500000)
10. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 2»(ref-606332-S39567147572014032500000)
11. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 2»(ref-606332-S40574423512014032500000)
12. SUPPORT AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY . Refer to «REMOVAL [08/2012 - ] - Step 14»(ref-606454-S13259800262014032500000)
13. REMOVE ENGINE REAR MOUNTING MEMBER See step 13
14. REMOVE TRANSFER DYNAMIC DAMPER See step 14
15. REMOVE TRANSFER OIL PAN See step 15
16. REMOVE TRANSFER VALVE BODY ASSEMBLY Remove the 4 bolts and the transfer upper valve body. Disconnect the transfer wire connector from the transfer control solenoid.
17. REMOVE TRANSFER CONTROL SOLENOID See step 31

1. INSTALL TRANSFER CONTROL SOLENOID See step 4
2. INSTALL TRANSFER VALVE BODY ASSEMBLY Connect the transfer wire connector to the transfer control solenoid. Install the transfer upper valve body with the 4 bolts. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
3. INSTALL TRANSFER OIL PAN See step 2
4. INSTALL TRANSFER DYNAMIC DAMPER See step 3
5. INSTALL ENGINE REAR MOUNTING MEMBER See step 4
6. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 3»(ref-606332-S06875084792014032500000)
7. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 4»(ref-606332-S20146793312014032500000)
8. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 4»(ref-606504-S21400057592014032500000)
9. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 4»(ref-606484-S23657827772014032500000)
10. INSTALL HEATED OXYGEN SENSOR (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 6»(ref-606504-S21400057592014032500000)
11. INSTALL HEATED OXYGEN SENSOR (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 6»(ref-606484-S23657827772014032500000)
12. INSTALL FRONT CENTER FLOOR BRACE (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 7»(ref-606504-S21400057592014032500000)
13. INSTALL FRONT CENTER FLOOR BRACE (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 7»(ref-606484-S23657827772014032500000)
14. INSTALL REAR NO. 1 FLOOR PANEL BRACE (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 8»(ref-606504-S21400057592014032500000)
15. INSTALL REAR NO. 1 FLOOR PANEL BRACE (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 8»(ref-606484-S23657827772014032500000)
16. ADD AUTOMATIC TRANSMISSION FLUID . Refer to «INSTALLATION [08/2012 - ] - Step 26»(ref-606454-S14780040612014032500000)
17. CHECK FOR EXHAUST GAS LEAKS

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1. DRAIN AUTOMATIC TRANSMISSION FLUID . Refer to «REMOVAL [08/2012 - ] - Step 3»(ref-606454-S13259800262014032500000)
2. REMOVE REAR NO. 1 FLOOR PANEL BRACE (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 3»(ref-606504-S18686819902014032500000)
3. REMOVE REAR NO. 1 FLOOR PANEL BRACE (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 3»(ref-606484-S00600307052014032500000)
4. REMOVE FRONT CENTER FLOOR BRACE (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 4»(ref-606504-S18686819902014032500000)
5. REMOVE FRONT CENTER FLOOR BRACE (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 4»(ref-606484-S00600307052014032500000)
6. DISCONNECT HEATED OXYGEN SENSOR (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 6»(ref-606504-S18686819902014032500000)
7. DISCONNECT HEATED OXYGEN SENSOR (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 6»(ref-606484-S00600307052014032500000)
8. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 7»(ref-606504-S18686819902014032500000)
9. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 7»(ref-606484-S00600307052014032500000)
10. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 2»(ref-606332-S39567147572014032500000)
11. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 2»(ref-606332-S40574423512014032500000)
12. SUPPORT AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY . Refer to «REMOVAL [08/2012 - ] - Step 14»(ref-606454-S13259800262014032500000)
13. REMOVE ENGINE REAR MOUNTING MEMBER See step 13
14. REMOVE TRANSFER DYNAMIC DAMPER See step 14
15. REMOVE TRANSFER OIL PAN See step 15
16. REMOVE TRANSFER VALVE BODY ASSEMBLY See step 16
17. REMOVE TRANSFER CONTROL SOLENOID Remove the bolt, solenoid lock plate and transfer control solenoid.

Scheme 120

1. INSPECT TRANSFER CONTROL SOLENOID Connect the battery's positive (+) terminal and a bulb of 12 V - 21 W to terminal 1 as shown. Connect the battery's negative (-) terminal to terminal 2 and check if the solenoid operates. OK The solenoid operates and operating sound is heard. Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition Terminal 1 - Terminal 2 5.0 to 5.6 ohms If the resistance is not within the specified range, replace the transfer control solenoid.

1. INSTALL TRANSFER CONTROL SOLENOID Install the transfer control solenoid and solenoid lock plate to the transfer upper valve body with the bolt. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) HINT: Install the solenoid lock plate into the cutout on the transfer control solenoid.
2. INSTALL TRANSFER VALVE BODY ASSEMBLY See step 2
3. INSTALL TRANSFER OIL PAN See step 2
4. INSTALL TRANSFER DYNAMIC DAMPER See step 3
5. INSTALL ENGINE REAR MOUNTING MEMBER See step 4
6. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 3»(ref-606332-S06875084792014032500000)
7. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 4»(ref-606332-S20146793312014032500000)
8. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 4»(ref-606504-S21400057592014032500000)
9. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 4»(ref-606484-S23657827772014032500000)
10. INSTALL HEATED OXYGEN SENSOR (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 6»(ref-606504-S21400057592014032500000)
11. INSTALL HEATED OXYGEN SENSOR (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 6»(ref-606484-S23657827772014032500000)
12. INSTALL FRONT CENTER FLOOR BRACE (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 7»(ref-606504-S21400057592014032500000)
13. INSTALL FRONT CENTER FLOOR BRACE (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 7»(ref-606484-S23657827772014032500000)
14. INSTALL REAR NO. 1 FLOOR PANEL BRACE (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 8»(ref-606504-S21400057592014032500000)
15. INSTALL REAR NO. 1 FLOOR PANEL BRACE (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 8»(ref-606484-S23657827772014032500000)
16. ADD AUTOMATIC TRANSMISSION FLUID . Refer to «INSTALLATION [08/2012 - ] - Step 26»(ref-606454-S14780040612014032500000)
17. CHECK FOR EXHAUST GAS LEAKS

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

1. DRAIN AUTOMATIC TRANSMISSION FLUID . Refer to «REMOVAL [08/2012 - ] - Step 3»(ref-606454-S13259800262014032500000)
2. REMOVE REAR NO. 1 FLOOR PANEL BRACE (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 3»(ref-606504-S18686819902014032500000)
3. REMOVE REAR NO. 1 FLOOR PANEL BRACE (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 3»(ref-606484-S00600307052014032500000)
4. REMOVE FRONT CENTER FLOOR BRACE (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 4»(ref-606504-S18686819902014032500000)
5. REMOVE FRONT CENTER FLOOR BRACE (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 4»(ref-606484-S00600307052014032500000)
6. DISCONNECT HEATED OXYGEN SENSOR (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 6»(ref-606504-S18686819902014032500000)
7. DISCONNECT HEATED OXYGEN SENSOR (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 6»(ref-606484-S00600307052014032500000)
8. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 7»(ref-606504-S18686819902014032500000)
9. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 7»(ref-606484-S00600307052014032500000)
10. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR (for 4GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 2»(ref-606332-S39567147572014032500000)
11. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR (for 2GR-FSE) . Refer to «REMOVAL [08/2012 - ] - Step 2»(ref-606332-S40574423512014032500000)
12. SUPPORT AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY . Refer to «REMOVAL [08/2012 - ] - Step 14»(ref-606454-S13259800262014032500000)
13. REMOVE ENGINE REAR MOUNTING MEMBER Remove the 4 bolts, 3 nuts and engine rear mounting member.
14. REMOVE TRANSFER DYNAMIC DAMPER Remove the 2 bolts and the transfer dynamic damper.
15. REMOVE TRANSFER OIL PAN Remove the 9 bolts. Insert the blade of oil pan seal cutter between the transfer oil pan and transfer case. Cut through the sealer and remove the transfer oil pan. NOTE: Do not damage the contact surface of the transfer oil pan. Remove the transfer oil cleaner magnet from the transfer oil pan. NOTE: Clean the inside of the oil pan thoroughly, removing all metal shavings, sludge and any other foreign objects. Remove any metal shavings from the magnet.
16. REMOVE TRANSFER WIRE Remove the 4 bolts and the transfer upper valve body. Disconnect the 2 transfer wire connectors. Remove the bolt and the transfer wire.

Scheme 127

1. INSPECT TRANSFER WIRE Disconnect the transfer wire connector. Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition i1-1 - i1-2 5.0 to 5.5 ohms i1-1 - Body ground 1 Mohms or higher i1-2 - Body ground 1 Mohms or higher If the resistance is not specified, replace the transfer wire.

1. INSTALL TRANSFER WIRE Coat the transfer wire O-ring with ATF. Install the transfer wire with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the 2 transfer wire connectors to the transfer control solenoid. Install the transfer upper valve body with the 4 bolts. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
2. INSTALL TRANSFER OIL PAN Install the transfer oil cleaner magnet to the transfer oil pan. Remove all residual FIPG material from the contact surfaces using gasoline or alcohol. Apply seal packing to the transfer chain case front as shown. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Temporarily tighten the 9 bolts in several steps, and then tighten them to the specified torque. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
3. INSTALL TRANSFER DYNAMIC DAMPER Install the transfer dynamic damper with the 2 bolts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
4. INSTALL ENGINE REAR MOUNTING MEMBER Install the engine rear mounting member with the 4 bolts and 3 nuts. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) (Bolt) Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) (Nut)
5. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 3»(ref-606332-S06875084792014032500000)
6. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 4»(ref-606332-S20146793312014032500000)
7. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 4»(ref-606504-S21400057592014032500000)
8. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 4»(ref-606484-S23657827772014032500000)
9. INSTALL HEATED OXYGEN SENSOR (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 6»(ref-606504-S21400057592014032500000)
10. INSTALL HEATED OXYGEN SENSOR (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 6»(ref-606484-S23657827772014032500000)
11. INSTALL FRONT CENTER FLOOR BRACE (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 7»(ref-606504-S21400057592014032500000)
12. INSTALL FRONT CENTER FLOOR BRACE (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 7»(ref-606484-S23657827772014032500000)
13. INSTALL REAR NO. 1 FLOOR PANEL BRACE (for 4GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 8»(ref-606504-S21400057592014032500000)
14. INSTALL REAR NO. 1 FLOOR PANEL BRACE (for 2GR-FSE) . Refer to «INSTALLATION [08/2012 - ] - Step 8»(ref-606484-S23657827772014032500000)
15. ADD AUTOMATIC TRANSMISSION FLUID . Refer to «INSTALLATION [08/2012 - ] - Step 26»(ref-606454-S14780040612014032500000)
16. CHECK FOR EXHAUST GAS LEAKS

Scheme 128

Scheme 129

Scheme 130

Scheme 131

1. REMOVE FRONT DOOR SCUFF PLATE RH (w/o Illumination) HINT: Use the same procedures for the RH side and the LH side. Refer to «REMOVAL [08/2012 - ] - Step 24»(ref-606515-S34598305682014032500000) .
2. REMOVE FRONT DOOR SCUFF PLATE RH (w/ Illumination) HINT: Use the same procedures for the RH side and the LH side. Refer to «REMOVAL [08/2012 - ] - Step 25»(ref-606515-S34598305682014032500000) .
3. REMOVE FRONT DOOR OPENING TRIM COVER RH . Refer to «REMOVAL [08/2012 - ] - Step 35»(ref-606515-S34598305682014032500000)
4. REMOVE SIDE INSTRUMENT PANEL RH . Refer to «REMOVAL [08/2012 - ] - Step 36»(ref-606515-S34598305682014032500000)
5. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to «REMOVAL [08/2012 - ] - Step 37»(ref-606515-S34598305682014032500000)
6. REMOVE 4WD CONTROL ECU Turn back the front floor carpet assembly. Disengage the 2 clips and separate the junction connector. Remove the bolt and nut. Disconnect the clamp and connector, and remove the 4WD control ECU.

1. INSTALL 4WD CONTROL ECU Connect the connector and clamp to the 4WD control ECU. Install the 4WD control ECU with the bolt and nut. Bolt Torque: 14 N*m (137 kgf*cm, 10 ft.*lbf) Nut Torque: 6.0 N*m (61 kgf*cm, 54 in.*lbf) Connect the junction connector with the 2 clips.
2. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY . Refer to «INSTALLATION [08/2012 - ] - Step 16»(ref-606515-S07334205762014032500000)
3. INSTALL SIDE INSTRUMENT PANEL RH . Refer to «INSTALLATION [08/2012 - ] - Step 17»(ref-606515-S07334205762014032500000)
4. INSTALL FRONT DOOR OPENING TRIM COVER RH . Refer to «INSTALLATION [08/2012 - ] - Step 18»(ref-606515-S07334205762014032500000)
5. INSTALL FRONT DOOR SCUFF PLATE RH (w/o Illumination) HINT: Use the same procedures for the RH side and the LH side. Refer to «INSTALLATION [08/2012 - ] - Step 28»(ref-606515-S07334205762014032500000) .
6. INSTALL FRONT DOOR SCUFF PLATE RH (w/ Illumination) HINT: Use the same procedures for the RH side and the LH side. Refer to «INSTALLATION [08/2012 - ] - Step 29»(ref-606515-S07334205762014032500000) .