Transfer Case (Service Information): Other Lexus IS III

PROCEDURE

1. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY Refer to «REMOVAL [04/2013 - ]»(ref-665725-S17633399262014102400000)

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1. REMOVE TRANSFER OIL PAN SUB-ASSEMBLY Remove the 9 bolts. Insert the blade of an oil pan seal cutter between the transfer oil pan sub-assembly and transfer case sub-assembly. Cut through the sealer and remove the transfer oil pan sub-assembly. NOTE: Do not damage the contact surface of the transfer oil pan sub-assembly. Remove the transfer oil cleaner magnet from the transfer oil pan sub-assembly. NOTE: Clean the inside of the transfer oil pan sub-assembly thoroughly, removing all metal shavings, sludge and any other foreign objects. Remove any metal shavings from the transfer oil cleaner magnet.
2. REMOVE TRANSFER CONTROL VALVE BODY ASSEMBLY Remove the 4 bolts and transfer control valve body assembly. Disconnect the connector from the transfer control solenoid assembly. *1 Connector
3. REMOVE TRANSFER CONTROL SOLENOID ASSEMBLY See step 9
4. REMOVE TRANSFER TRANSMISSION WIRE Remove the bolt and transfer transmission wire.
5. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR Using SST, remove the transfer extension housing dust deflector. *a Turn *b Hold SST: 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09955-04051 09958-04011 NOTE: Apply molybdenum grease to the threads and tip of SST center bolt before use.
6. REMOVE TRANSFER CASE SUB-ASSEMBLY Remove the 8 bolts and clamp. *1 Clamp Using a plastic-faced hammer, tap the transfer case sub-assembly to remove it. Remove the bolt and clamp. *1 Clamp
7. REMOVE TRANSFER REAR OUTPUT SHAFT ASSEMBLY Remove the transfer rear output shaft assembly.
8. REMOVE FLANGE YOKE ASSEMBLY Using SST and a hammer, release the staked part of the flange yoke nut. SST: 09930-00010 NOTE: Be sure to use SST with the tapered surface facing the shaft. Do not grind the tip of SST with a grinder, etc. Completely loosen the staked part of the flange yoke nut when removing it. Do not damage the threads of the transfer drive sprocket. Install the 30 mm socket wrench, extension bar and SST to the flange yoke assembly in the order shown in the illustration. *1 Flange Yoke Assembly SST: 09213-54015 91651-60855 NOTE: When securing SST and flange yoke assembly, it in recommended to use M8 X P1.25 bolts with a length of approximately 55 mm. Using SST, hold the flange yoke assembly. *a Turn *b Hold SST: 09330-00021 Using a 30 mm socket wrench, remove the flange yoke nut. Remove the flange yoke assembly.
9. REMOVE TRANSFER REAR CHAIN CASE ASSEMBLY Remove the 10 bolts. Tap the 3 protrusions of the transfer rear chain case assembly gently with a brass bar and hammer to loosen, and remove it. NOTE: Do not damage the transfer rear chain case assembly.
10. REMOVE TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVE SPROCKET SUB-ASSEMBLY AND TRANSFER FRONT DRIVE CLUTCH SLEEVE SUB-ASSEMBLY Remove the transfer front drive chain, transfer drive sprocket sub-assembly and transfer front drive clutch sleeve sub-assembly. Remove the transfer front drive chain from the transfer drive sprocket sub-assembly and transfer front drive clutch sleeve sub-assembly.
11. REMOVE TRANSFER FRONT CHAIN CASE Remove the 6 bolts and transfer front chain case. HINT: If necessary, tap the transfer front chain case with a plastic-faced hammer to loosen and remove it.
12. REMOVE TRANSFER CASE OIL SEAL Using a screwdriver, pry out the transfer case oil seal from the transfer case sub-assembly. *1 Protective Tape HINT: Tape the screwdriver tip before use.
13. REMOVE TRANSFER CASE BEARING Using SST, remove the transfer case bearing from the transfer case sub-assembly. SST: 09308-00010
14. REMOVE TRANSFER BAFFLE VALVE SUB-ASSEMBLY Remove the bolt and transfer baffle valve sub-assembly from the transfer rear chain case assembly.
15. REMOVE TRANSFER CHAIN CASE GOVERNOR APPLY GASKET Remove the screw, O-ring and 2 transfer chain case governor apply gaskets from the transfer front chain case. *A for Front Side *B for Rear Side *1 Transfer Chain Case Governor Apply Gasket *2 O-ring *3 Screw Remove the 2 transfer chain case governor apply gaskets from the transfer rear chain case assembly.
16. REMOVE TRANSFER CHAIN CASE OIL SEAL Using a screwdriver, pry out the transfer chain case oil seal from the transfer front chain case. *1 Protective Tape HINT: Tape the screwdriver tip before use.
17. REMOVE TRANSFER REAR OUTPUT SHAFT ASSEMBLY AND CENTER DIFFERENTIAL CARRIER ASSEMBLY Remove the transfer rear output shaft assembly and center differential carrier assembly from the transfer direct clutch drum sub-assembly. *1 Transfer Rear Output Shaft Assembly *2 Center Differential Carrier Assembly *3 Transfer Direct Clutch Drum Sub-assembly
18. REMOVE TRANSFER REAR OUTPUT SHAFT BEARING Remove the transfer rear output shaft bearing from the center differential carrier assembly.
19. REMOVE CENTER DIFFERENTIAL CLUTCH DISC SET Using a screwdriver, remove the transfer direct clutch flange snap ring from the transfer direct clutch drum sub-assembly. *1 Protective Tape HINT: Tape the screwdriver tip before use. Remove the 2 center differential clutch disc flanges and center differential clutch disc set from the transfer direct clutch drum sub-assembly. *1 Center differential clutch disc flange (No. 1) *2 Center differential clutch disc set (Discs) *3 Center differential clutch disc set (Plates) *4 Center differential clutch disc flange (No. 2)
20. REMOVE CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER Place SST on the center differential clutch pressure balancer and compress the transfer direct clutch return spring assembly with a press. *1 Transfer Direct Clutch Return Spring Snap Ring SST: 09350-30020 09350-07040 Using SST, remove the transfer direct clutch return spring snap ring. SST: 09350-30020 09350-07040 09350-07070 Remove the center differential clutch pressure balancer from the transfer direct clutch drum sub-assembly.
21. REMOVE TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY Remove the transfer direct clutch return spring assembly from the transfer direct clutch drum sub-assembly.
22. REMOVE CENTER DIFFERENTIAL CLUTCH PISTON Install the transfer direct clutch drum sub-assembly to the transfer center support assembly. *1 Transfer Direct Clutch Drum Sub-assembly *2 Transfer Center Support Assembly While pushing down evenly on the center differential clutch piston, apply air (200 kPa, 2.0 kgf/cm 2 , 19 psi) at the oil hole on the transfer rear chain case assembly as shown in the illustration to remove the center differential clutch piston from the transfer direct clutch drum sub-assembly. *1 Center Differential Clutch Piston *2 Oil Hole Remove the transfer direct clutch drum sub-assembly from the transfer center support assembly.
23. REMOVE TRANSFER DIRECT CLUTCH PISTON O-RING Remove the 2 transfer direct clutch piston O-rings from the center differential clutch piston. *1 Transfer Direct Clutch Piston O-ring
24. REMOVE TRANSFER CENTER SUPPORT ASSEMBLY Remove the 5 bolts and transfer center support assembly. Remove the 2 screws and 2 O-rings from the transfer rear chain case assembly.
25. REMOVE TRANSFER CENTER SUPPORT SEAL RING Remove the 2 transfer center support seal rings from the transfer center support assembly. *1 Transfer Center Support Seal Ring
26. REMOVE TRANSFER DRIVEN SPROCKET BEARING Using SST and a press, remove the transfer driven sprocket bearing from the transfer driven sprocket. *1 Transfer Driven Sprocket Bearing SST: 09950-00020 Using SST and a press, remove the transfer driven sprocket bearing from the transfer driven sprocket. *1 Transfer Driven Sprocket Bearing SST: 09950-00020 SST: 09950-60010 09951-00530 SST: 09950-70010 09951-07100
27. REMOVE TRANSFER DRIVEN SPROCKET BEARING Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket. *1 Transfer Drive Sprocket Bearing SST: 09950-00020 SST: 09950-60010 09951-00480 SST: 09950-70010 09951-07100 Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket. *1 Transfer Drive Sprocket Bearing SST: 09950-00020 SST: 09950-60010 09951-00530 SST: 09950-70010 09951-07100

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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 (0.00788 to 0.0196 in.) If the clearance is more than the standard clearance, replace the center differential carrier assembly.
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. ATF Toyota Genuine ATF WS
3. INSPECT TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY Using a vernier caliper, measure the free length of the spring together with the spring seat. Standard Free Length 15.5 mm (0.610 in.) If the free length is shorter than the standard free length, replace the transfer direct clutch return spring assembly.
4. INSPECT TRANSFER DIRECT CLUTCH DRUM SUB-ASSEMBLY Using a cylinder gauge, measure the inside diameter of the transfer direct clutch drum sub-assembly. Standard inside diameter 65.00 to 65.06 mm (2.560 to 2.561 in.) If the inside diameter is more than the standard inside diameter, replace the transfer direct clutch drum sub-assembly.
5. INSPECT TRANSFER CENTER SUPPORT ASSEMBLY Using a cylinder gauge, measure the inside diameter of the transfer center support assembly. Standard inside diameter 49.9 to 50.1 mm (1.965 to 1.972 in.) If the inside diameter is more than the standard inside diameter, replace the transfer center support assembly.

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1. INSTALL TRANSFER DRIVE SPROCKET BEARING Using SST and a press, install a new transfer drive sprocket bearing until its surface is flush with the transfer drive sprocket sub-assembly. *1 Transfer Drive Sprocket Bearing SST: 09316-20011 SST: 09950-60010 09951-00640 SST: 09950-70010 09951-07100 Using SST and a press, install a new transfer drive sprocket bearing until its surface is flush with the transfer drive sprocket sub-assembly. *1 Transfer Drive Sprocket Bearing *a Shield Facing Downward SST: 09316-60011 09316-00011 Install the transfer drive sprocket bearing with the shield facing downward.
2. INSTALL TRANSFER DRIVEN SPROCKET BEARING Using SST and a press, install a new transfer driven sprocket bearing until its surface is flush with the transfer front drive clutch sleeve sub-assembly. *1 Transfer Driven Sprocket Bearing SST: 09316-20011 SST: 09950-60010 09951-00640 SST: 09950-70010 09951-07100 Using SST and a press, install a new transfer driven sprocket bearing until its surface is flush with the transfer front drive clutch sleeve sub-assembly. *1 Transfer Driven Sprocket Bearing SST: 09316-60011 09316-00011 09316-00041
3. INSTALL TRANSFER CENTER SUPPORT SEAL RING Coat the 2 transfer center support seal rings with ATF. ATF Toyota Genuine ATF WS Compress the 2 transfer center support seal rings as shown in the illustration and install them into the grooves on the transfer center support assembly. NOTE: Do not expand the ring ends excessively. If any ring is damaged or deformed, replace it with a new one.
4. INSTALL TRANSFER CENTER SUPPORT ASSEMBLY Install the transfer center support assembly to the transfer rear chain case assembly with the 5 bolts. Torque: 25.5 N*m (260 kgf*cm, 19 ft.*lbf) Coat 2 new O-rings with ATF. ATF Toyota Genuine ATF WS Install the 2 O-rings to the screws. Install the 2 screws to the transfer rear chain case assembly. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
5. INSTALL TRANSFER DIRECT CLUTCH PISTON O-RING Coat 2 new transfer direct clutch piston O-rings with ATF. *1 Transfer Direct Clutch Piston O-ring ATF Toyota Genuine ATF WS Install the 2 transfer direct clutch piston O-rings to the center differential clutch piston. O-RING SIZE: Installation position Inner diameter mm (in.) Thickness mm (in.) Inner 56.45 to 57.45 (2.223 to 2.261) 2.54 to 2.70 (0.100 to 0.106) Outer 116.20 to 117.80 (4.575 to 4.637) 3.0 to 3.2 (0.119 to 0.125)
6. INSTALL CENTER DIFFERENTIAL CLUTCH PISTON Install the center differential clutch piston to the transfer direct clutch drum sub-assembly. NOTE: Do not damage the transfer direct clutch piston O-ring.
7. INSTALL TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY Install the transfer direct clutch return spring assembly to the transfer direct clutch drum sub-assembly.
8. INSTALL CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER Coat the rubber on the center differential clutch pressure balancer with ATF. *a Rubber ATF Toyota Genuine ATF WS Install the center differential clutch pressure balancer to the transfer direct clutch drum sub-assembly. Place SST on the center differential clutch pressure balancer, and compress the transfer direct clutch return spring assembly with a press. *1 Transfer Direct Clutch Return Spring Snap Ring SST: 09350-30020 09350-07040 Using SST, install the transfer direct clutch return spring snap ring. SST: 09350-30020 09350-07040 09350-07070
9. 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 sub-assembly. *1 Center Differential Clutch Disc Flange (No. 1) *2 Center Differential Clutch Disc Set (Discs) *3 Center Differential Clutch Disc Set (Plates) *4 Center Differential Clutch Disc Flange (No. 2) Install in the following order *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 -*3 - *2 - *4 NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes. ATF Toyota Genuine ATF WS Using a screwdriver with its tip taped, install the transfer direct clutch flange snap ring to the transfer direct clutch drum sub-assembly. *1 Protective Tape Install the transfer direct clutch drum sub-assembly to the transfer center support assembly. *1 Transfer Direct Clutch Drum Sub-assembly *2 Transfer Center Support Assembly Set the dial indicator perpendicular to the center differential clutch disc flange (No. 1). *1 Center Differential Clutch Disc Flange (No. 1) *2 Center Differential Clutch Pressure Balancer *3 Center Differential Clutch Piston *4 Oil Hole Apply air (200 kPa, 2.0 kgf/cm 2 , 19 psi) at the oil hole as shown in the illustration. Measure the pack clearance. Standard Clearance 0.40 to 0.80 mm (0.0158 to 0.0314 in.) HINT: Check that the center differential clutch 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). *1 Center Differential Clutch Disc Flange (No. 1) FLANGE THICKNESS: Mark Thickness mm (in.) 90 2.95 to 3.05 (0.117 to 0.120) 91 3.15 to 3.25 (0.125 to 0.127) 92 3.35 to 3.45 (0.132 to 0.135) Remove the transfer direct clutch drum sub-assembly from the transfer center support assembly. *1 Transfer Direct Clutch Drum Sub-assembly *2 Transfer Center Support Assembly
10. INSTALL TRANSFER REAR OUTPUT SHAFT BEARING Attach the 2 guides to install the transfer rear output shaft bearing to the center differential carrier assembly.
11. INSTALL TRANSFER REAR OUTPUT SHAFT ASSEMBLY AND CENTER DIFFERENTIAL CARRIER ASSEMBLY Install the transfer rear output shaft assembly and center differential carrier assembly to the transfer direct clutch drum sub-assembly. *1 Transfer Rear Output Shaft Assembly *2 Center Differential Carrier Assembly *3 Transfer Direct Clutch Drum Sub-assembly
12. INSTALL TRANSFER CHAIN CASE OIL SEAL Using SST and a hammer, install a new transfer chain case oil seal. *1 Transfer Chain Case Oil Seal *a Oil Seal Installation Depth SST: 09316-60011 09316-00011 09316-00071 Standard depth 5.6 to 6.2 mm (0.221 to 0.244 in.) Apply MP grease to the transfer chain case oil seal lip.
13. INSTALL TRANSFER CHAIN CASE GOVERNOR APPLY GASKET Coat 2 new transfer chain case governor apply gaskets with ATF. ATF Toyota Genuine ATF WS Install the 2 transfer chain case governor apply gaskets to the transfer rear chain case assembly. Coat a new O-ring and 2 new transfer chain case governor apply gaskets with ATF. *A for Front Side *B for Rear Side *1 Transfer Chain Case Governor Apply Gasket *2 O-ring *3 Screw ATF Toyota Genuine ATF WS Install the O-ring to the screw. Install the 2 transfer chain case governor apply gaskets and screw to the transfer front chain case. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
14. INSTALL TRANSFER BAFFLE VALVE SUB-ASSEMBLY Install the transfer baffle valve sub-assembly to the transfer rear chain case assembly with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
15. INSTALL TRANSFER CASE BEARING Using SST and a press, install a new transfer case bearing to the transfer case sub-assembly. *1 Transfer Case Bearing *a Bearing Installation Depth SST: 09950-60020 09951-00890 SST: 09950-70010 09951-07150 Standard depth 94.61 to 94.86 mm (3.725 to 3.734 in.)
16. INSTALL TRANSFER CASE OIL SEAL Using SST and a hammer, install a new transfer case oil seal. *1 Transfer Case Oil Seal *a Oil Seal Installation Depth SST: 09325-40010 Standard depth 2.3 to 2.7 mm (0.091 to 0.106 in.) Apply MP grease to the transfer case oil seal lip.
17. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR Using SST and a press, install a new transfer extension housing dust deflector until its surface is flush with the transfer case sub-assembly. SST: 09950-60020 09951-00910 SST: 09950-70010 09951-07150
18. INSTALL TRANSFER FRONT CHAIN CASE Clean the threads of the bolts and the transfer front chain case with non-residue solvent. *1 Seal Packing *a Seal Width 1.0 to 1.5 mm (0.04 to 0.06 in.) Apply seal packing 1281 to the transfer front chain case as shown in the illustration. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent NOTE: Reassemble the parts within 5 minutes of applying fresh FIPG material. Otherwise, the packing (FIPG) material must be removed and reapplied. Temporarily install the 6 bolts in several steps, and then tighten them to the specified torque. Torque: 33.9 N*m (346 kgf*cm, 25 ft.*lbf) HINT: Bolt length: Bolt A: 57 mm (2.244 in.) Bolt B: 74 mm (2.913 in.) Other Bolts: 45 mm (1.771 in.)
19. INSTALL TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVE SPROCKET SUB-ASSEMBLY AND TRANSFER FRONT DRIVE CLUTCH SLEEVE SUB-ASSEMBLY Install the transfer front drive chain to the transfer drive sprocket sub-assembly and transfer front drive clutch sleeve sub-assembly. Install the transfer front drive chain, transfer drive sprocket sub-assembly and transfer front drive clutch sleeve sub-assembly.
20. INSTALL TRANSFER REAR CHAIN CASE ASSEMBLY Clean the threads of the bolts and the transfer rear chain case assembly with non-residue solvent. *1 Seal Packing *a Seal Width 1.0 to 1.5 mm (0.04 to 0.06 in.) Apply seal packing 1281 to the transfer rear chain case assembly as shown in the illustration. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent NOTE: Reassemble the parts within 5 minutes of applying fresh FIPG material. Otherwise, the packing (FIPG) material must be removed and reapplied. Temporarily install the 10 bolts in several steps, and then tighten them to the specified torque. Bolt A Torque: 56.8 N*m (579 kgf*cm, 42 ft.*lbf) Bolt B, Bolt C and Other Bolts Torque: 33.9 N*m (346 kgf*cm, 25 ft.*lbf) HINT: Bolt length: Bolt A: 60 mm (2.362 in.) Bolt B: 50 mm (1.969 in.) Bolt C: 109 mm (4.291 in.) Other Bolts: 40 mm (1.574 in.)
21. INSTALL FLANGE YOKE ASSEMBLY Install the flange yoke assembly. Using SST, hold the flange yoke assembly. *a Turn *b Hold SST: 09213-54015 91651-60855 SST: 09330-00021 Using a 30 mm deep socket wrench, install a new flange yoke nut. Torque: 122.5 N*m (1249 kgf*cm, 90 ft.*lbf) Using a chisel and hammer, stake the flange yoke nut.
22. INSTALL TRANSFER REAR OUTPUT SHAFT ASSEMBLY Install the transfer rear output shaft assembly.
23. INSTALL TRANSFER CASE SUB-ASSEMBLY Install the clamp to the transfer case sub-assembly with the bolt. *1 Clamp Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Clean the threads of the bolts and the transfer case sub-assembly with non-residue solvent. *1 Seal Packing *a Seal Width 1.0 to 1.5 mm (0.04 to 0.06 in.) Apply seal packing 1281 to the transfer case sub-assembly as shown in the illustration. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent NOTE: Reassemble the parts within 5 minutes of applying fresh FIPG material. Otherwise, the packing (FIPG) material must be removed and reapplied. Temporarily install the 8 bolts and clamp in several steps, and then tighten them to the specified torque. *1 Clamp Torque: 33.9 N*m (346 kgf*cm, 25 ft.*lbf) HINT: Bolt length: Bolt A: 88 mm (3.465 in.) Bolt B: 40 mm (1.574 in.)
24. INSTALL TRANSFER TRANSMISSION WIRE Coat the transfer transmission wire O-ring with ATF. *1 Transfer Transmission Wire O-ring Coat with Toyota Genuine ATF WS ATF Toyota Genuine ATF WS Install the transfer transmission wire with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
25. INSTALL TRANSFER CONTROL SOLENOID ASSEMBLY See step 1
26. INSTALL TRANSFER CONTROL VALVE BODY ASSEMBLY Connect the connector to the transfer control solenoid assembly. *1 Connector Install the transfer control valve body assembly with the 4 bolts. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
27. INSTALL TRANSFER OIL PAN SUB-ASSEMBLY Install the transfer oil cleaner magnet to the transfer oil pan sub-assembly. *1 Transfer Oil Cleaner Magnet Clean the threads of the bolts and the transfer oil pan sub-assembly with non-residue solvent. *1 Seal Packing *a Seal Width 3.0 to 3.5 mm (0.12 to 0.14 in.) Apply seal packing 1281 to the transfer oil pan sub-assembly as shown in the illustration. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent NOTE: Reassemble the parts within 5 minutes of applying fresh FIPG material. Otherwise, the packing (FIPG) material must be removed and reapplied. Temporarily install 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)

1. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY Refer to «INSTALLATION [04/2013 - ]»(ref-665725-S27173768842014102400000)

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*1 AUTOMATIC WITH TRANSFER TRANSMISSION ASSEMBLY *2 FRONT NO. 1 FLOOR HEAT INSULATOR *3 ENGINE REAR MOUNTING MEMBER SUB-ASSEMBLY *4 TRANSFER CONTROL SOLENOID ASSEMBLY *5 TRANSFER CONTROL VALVE BODY ASSEMBLY *6 TRANSFER DYNAMIC DAMPER *7 TRANSFER OIL PAN SUB-ASSEMBLY *8 SOLENOID LOCK PLATE *9 TRANSFER OIL CLEANER MAGNET - - N*m (kgf*cm, ft*lbf) : Specified torque

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1. DRAIN AUTOMATIC TRANSMISSION FLUID Refer to «PROCEDURE - Step 1»(ref-665725-S09824746662014102400000)
2. REMOVE FRONT EXHAUST PIPE ASSEMBLY for 2GR-FSE: Refer to «REMOVAL [04/2013 - ]»(ref-665735-S41687587032014102400000) for 4GR-FSE: Refer to «REMOVAL [04/2013 - ]»(ref-665769-S08344338672014102400000)
3. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR Refer to «PROCEDURE - Step 2»(ref-665533-S10549293592014102400000)
4. SUPPORT AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY Refer to «PROCEDURE - Step 11»(ref-665725-S20409826952014102400000)
5. REMOVE ENGINE REAR MOUNTING MEMBER SUB-ASSEMBLY Remove the 4 bolts and separate the rear engine mounting member sub-assembly from the body. Remove the 3 nuts and rear engine mounting member from the automatic with transfer transmission assembly.
6. REMOVE TRANSFER DYNAMIC DAMPER Remove the 2 bolts and the transfer dynamic damper.
7. REMOVE TRANSFER OIL PAN SUB-ASSEMBLY Remove the 9 bolts. Insert the blade of an oil pan seal cutter between the transfer oil pan sub-assembly and transfer case sub-assembly. Cut through the sealer and remove the transfer oil pan sub-assembly. NOTE: Do not damage the contact surface of the transfer oil pan sub-assembly. Remove the transfer oil cleaner magnet from the transfer oil pan sub-assembly. NOTE: Clean the inside of the transfer oil pan sub-assembly thoroughly, removing all metal shavings, sludge and any other foreign objects. Remove any metal shavings from the transfer oil cleaner magnet.
8. REMOVE TRANSFER CONTROL VALVE BODY ASSEMBLY Remove the 4 bolts and the transfer control valve body assembly. *1 Connector Disconnect the connector from the transfer control solenoid assembly.
9. REMOVE TRANSFER CONTROL SOLENOID ASSEMBLY Remove the bolt, solenoid lock plate and transfer control solenoid assembly. *1 Transfer Control Solenoid Assembly *2 Solenoid Lock Plate

1. INSPECT TRANSFER CONTROL SOLENOID ASSEMBLY Measure the resistance according to the value(s) in the table below. *a Component without harness connected (Transfer Control Solenoid Assembly) Standard Resistance Tester Connection Condition Specified Condition 1 - 2 20°C (68°F) 5.0 to 5.6 ohms If the resistance is not within the specified range, replace the transfer control solenoid assembly. Connect a positive (+) lead with a 21 W bulb to terminal 1 and a negative (-) lead to terminal 2 of the transfer control solenoid assembly connector and then check the operation of the solenoid. OK The solenoid operates and an operating sound is heard. If the resistance is not within the specified range, replace the transfer control solenoid assembly.

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1. INSTALL TRANSFER CONTROL SOLENOID ASSEMBLY Install the transfer control solenoid assembly and solenoid lock plate to the transfer control valve body assembly with the bolt. *1 Transfer Control Solenoid Assembly *2 Solenoid Lock Plate *a Cutout 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 assembly.
2. INSTALL TRANSFER CONTROL VALVE BODY ASSEMBLY Connect the connector to the transfer control solenoid assembly. Install the transfer control valve body assembly with the 4 bolts. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
3. INSTALL TRANSFER OIL PAN SUB-ASSEMBLY Install the transfer oil cleaner magnet to the transfer oil pan sub-assembly. *1 Transfer Oil Cleaner Magnet Clean the threads of the bolts and the transfer oil pan sub-assembly with non-residue solvent. Apply seal packing 1281 to the transfer oil pan sub-assembly as shown in the illustration. *1 Seal Packing *a Seal Width 3.0 to 3.5 mm (0.12 to 0.14 in.) Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent NOTE: Reassemble the parts within 5 minutes of applying fresh FIPG material. Otherwise, the packing (FIPG) material must be removed and reapplied. Temporarily install 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)
4. INSTALL TRANSFER DYNAMIC DAMPER Install the transfer dynamic damper with the 2 bolts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
5. INSTALL ENGINE REAR MOUNTING MEMBER SUB-ASSEMBLY Install the rear engine mounting member with the 4 bolts and 3 nuts. Bolt Torque: 34.7 N*m (354 kgf*cm, 26 ft.*lbf) Nut Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
6. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR Refer to «PROCEDURE - Step 4»(ref-665533-S24896689832014102400000)
7. INSTALL FRONT EXHAUST PIPE ASSEMBLY for 2GR-FSE: Refer to «INSTALLATION [04/2013 - ]»(ref-665735-S23360003792014102400000) for 4GR-FSE: Refer to «INSTALLATION [04/2013 - ]»(ref-665769-S36608545392014102400000)
8. ADD AUTOMATIC TRANSMISSION FLUID Refer to «PROCEDURE - Step 6»(ref-665725-S22212662302014102400000)
9. INSPECT FOR EXHAUST GAS LEAK Refer to «PROCEDURE - Step 8»(ref-665769-S08378769372014102400000)

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*1 TRANSFER CONTROL VALVE BODY ASSEMBLY *2 TRANSFER TRANSMISSION WIRE *3 AUTOMATIC WITH TRANSFER TRANSMISSION ASSEMBLY - - N*m (kgf*cm, ft*lbf) : Specified torque Toyota Genuine ATF WS

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1. DRAIN AUTOMATIC TRANSMISSION FLUID Refer to «PROCEDURE - Step 1»(ref-665725-S09824746662014102400000)
2. REMOVE TRANSFER CONTROL VALVE BODY ASSEMBLY Refer to «REMOVAL [04/2013 - ]»(ref-665804-S09737998592014102400000)
3. REMOVE TRANSFER TRANSMISSION WIRE Disconnect the connector. *1 Connector Remove the bolt and the transfer transmission wire.

1. INSTALL TRANSFER TRANSMISSION WIRE Coat the transfer transmission wire O-ring with ATF. *1 Transfer Transmission Wire O-ring Coat with Toyota Genuine ATF WS ATF Toyota Genuine ATF WS Install the transfer transmission wire with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the connector to the transfer control solenoid assembly.
2. INSTALL TRANSFER CONTROL VALVE BODY ASSEMBLY Refer to «INSTALLATION [04/2013 - ]»(ref-665804-S27481559062014102400000)
3. ADD AUTOMATIC TRANSMISSION FLUID Refer to «PROCEDURE - Step 6»(ref-665725-S22212662302014102400000)
4. INSPECT FOR EXHAUST GAS LEAK Refer to «PROCEDURE - Step 8»(ref-665769-S08378769372014102400000)

Scheme 77

*1 4WD ECU ASSEMBLY *2 NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf): Specified torque

Scheme 78

1. PRECAUTION NOTE: After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to «INITIALIZATION [04/2013 - ]»(ref-665529-S01115916402014102400000)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [04/2013 - ]»(ref-665529-S01115916402014102400000)
3. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Refer to «PROCEDURE - Step 23»(ref-665744-S19081852182014102400000)
4. REMOVE 4WD ECU ASSEMBLY Disconnect the 4WD ECU assembly connector. Remove the bolt and 4WD ECU assembly from the blower assembly.

1. INSTALL 4WD ECU ASSEMBLY Install the 4WD ECU assembly to the blower assembly with the bolt. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) Connect the 4WD ECU assembly connector.
2. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Refer to «PROCEDURE - Step 20»(ref-665744-S38149584352014102400000)
3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [04/2013 - ]»(ref-665529-S01115916402014102400000)