Transfer Case System: Overhaul Lexus LX J100 рестайлинг

REASSEMBLY

HINT

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

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1. INSTALL FRONT BALL BEARING Using SST and a press, install a new front ball bearing. SST 09316-60011 (09316-00011) Select a snap ring that will allow the minimum axial play. Using a snap ring expander, install a new snap ring.
2. INSTALL REAR BALL BEARING Using SST and a press, install the rear ball bearing. SST 09316-60011 (09316-00011, 09316-00031) Select a snap ring that will allow the minimum axial play. Using a snap ring expander, install a new snap ring.

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1. INSPECT IDLER LOW GEAR RADIAL AND THRUST CLEARANCE Using a feeler gauge, measure the idler low gear thrust clearance. Standard clearance: 0.125 - 0.275 mm (0.00492 - 0.01083 in.) Maximum clearance: 0.275 mm (0.01083 in.) Using a dial indicator, measure the idler low gear radial clearance. Standard clearance: 0.015 - 0.068 mm (0.00059 - 0.00268 in.) Maximum clearance: 0.068 mm (0.00268 in.)
2. REMOVE FRONT TAPER ROLLER BEARING Using SST, remove the front taper roller bearing. SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00330) NOTE: Set the claw of SST to the bearing inner race securely.
3. REMOVE REAR TAPER ROLLER BEARING Using SST, a press and socket wrench, remove the rear taper roller bearing. SST 09950-00020 NOTE: Set the claw of SST to the bearing inner race securely.
4. REMOVE IDLER LOW GEAR AND NEEDLE ROLLER BEARING FROM IDLER GEAR
5. REMOVE HIGH AND LOW CLUTCH SLEEVE FROM IDLER GEAR

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1. INSPECT IDLER GEAR Using a micrometer, measure the idler gear diameter. Standard diameter: 38.48 - 38.50 mm (1.5149 - 1.5157 in.) Maximum diameter: 38.50 mm (1.5157 in.)
2. INSPECT IDLER LOW GEAR Using a cylinder gauge, measure the idler low gear diameter. Standard diameter: 45.52 - 45.54 mm (1.7922 - 1.7930 in.) Maximum diameter: 45.54 mm (1.7930 in.)

HINT

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

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1. INSTALL FRONT TAPER ROLLER BEARING Using SST and a press, install the front taper roller bearing. SST 09316-60011 (09316-00011, 09316-00031)
2. INSTALL HIGH AND LOW CLUTCH SLEEVE HINT: Make sure to install the high and low clutch sleeve in the correct direction.
3. INSTALL NEEDLE ROLLER BEARING AND IDLER LOW GEAR TO IDLER GEAR Apply gear oil to the needle roller bearing. Install the needle roller bearing and idler low gear.
4. INSTALL REAR TAPER ROLLER BEARING Using SST and a press, install the rear taper roller bearing. SST 09316-60011 (09316-00011, 09316-00071)
5. INSPECT IDLER LOW GEAR RADIAL AND THRUST CLEARANCE (See «INSPECTION»(ref-209812-S22945854872005121100000) )

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1. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE Using a feeler gauge, measure the high speed output gear thrust clearance. Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.) Maximum clearance: 0.25 mm (0.0098 in.) Using a dial indicator, measure the high speed output gear radial clearance. Standard clearance: 0.035 - 0.091 mm (0.00138 - 0.00358 in.) Maximum clearance: 0.091 mm (0.00358 in.)
2. REMOVE FRONT DRIVE GEAR PIECE Using a snap ring expander, remove the snap ring. Using SST and a press, remove the front drive gear piece. SST 09950-00020, 09950-60010 (09951-00320) NOTE: Be careful not to drop the center differential assembly.
3. REMOVE FRONT TAPER ROLLER BEARING Using SST and a press, remove the front taper roller bearing. SST 09950-00020 NOTE: Set the claw of SST to the bearing inner race securely.
4. REMOVE HIGH SPEED OUTPUT GEAR
5. REMOVE 2 NEEDLE ROLLER BEARINGS
6. REMOVE HIGH AND LOW CLUTCH SLEEVE
7. REMOVE HIGH SPEED OUTPUT GEAR BUSHING AND CLUTCH HUB Using SST, remove the high speed output gear bushing and clutch hub. SST 09950-00020, 09950-00030, 09950-60010 (09951-00320) Using a magnetic finger, remove the straight pin from the differential front case.
8. REMOVE REAR TAPER ROLLER BEARING Using SST and a press, remove the rear taper roller bearing. SST 09950-00020, 09950-60010 (09951-00320) NOTE: Set the claw of SST to the bearing inner race securely.
9. REMOVE DIFFERENTIAL REAR CASE Remove the 12 bolts and differential rear case.
10. REMOVE THRUST WASHER AND REAR SIDE GEAR
11. REMOVE PINION SHAFT, 2 PINION GEARS AND 2 THRUST WASHERS Remove the straight pin from the pinion shaft. Remove the pinion shaft, 2 pinion gears and thrust washers. Remove the front side gear and thrust washer.
12. REMOVE LOW GEAR Using a plastic hammer, tap and remove the low gear. NOTE: Be careful not to damage the low gear.

HINT

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

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1. INSTALL LOW GEAR Clean the contact surface of the differential case. Heat the low gear in boiling water. Carefully remove the low gear from the water. After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case.
2. INSTALL THRUST WASHER AND FRONT SIDE GEAR
3. INSTALL PINION SHAFT, 2 PINION GEARS AND 2 THRUST WASHERS Install the pinion shaft, 2 pinion gears and thrust washers to the differential front case. Using a dial indicator, measure the front case backlash. HINT: Push the pinion shaft. Maximum backlash: 0.05 mm (0.0020 in.) If the backlash is not within the specification, replace the thrust washer with one of the correct size and reinstall the thrust washer. In the same way, measure the rear case backlash.
4. INSTALL STRAIGHT PIN TO PINION SHAFT
5. INSTALL REAR SIDE GEAR AND THRUST WASHER
6. INSTALL DIFFERENTIAL REAR CASE Install the differential rear case and 12 set bolts. Torque: 88 N.m (900 kgf.cm, 65 ft.lbf) Turn the pinion gear. Loosen the 12 rear case set bolts. Torque the 12 rear case set bolts. Torque: 98 N.m (1,000 kgf.cm, 72 ft.lbf)
7. INSTALL REAR TAPER ROLLER BEARING Using SST and a press, install the rear taper roller bearing. SST 09316-12010
8. INSTALL CLUTCH HUB Using SST and a press, install the clutch hub. SST 09316-12010, 09316-60011 (09316-00011)
9. INSTALL HIGH SPEED OUTPUT GEAR BUSHING Apply MP grease to the straight pin. Install the straight pin (Scheme 112) Using SST and a press, install the high speed output gear bushing. SST 09316-12010, 09316-60011 (09316-00011) NOTE: Before pressing on the differential front case, align the groove on the bushing with the pin on the shaft.
10. INSTALL HIGH AND LOW CLUTCH SLEEVE HINT: Make sure to install the high and low clutch sleeve in the correct direction.
11. INSTALL NEEDLE ROLLER BEARING AND HIGH SPEED OUTPUT GEAR Apply gear oil to the needle roller bearing. Install the needle roller bearing and high speed output gear.
12. INSTALL FRONT TAPER ROLLER BEARING Using SST and a press, install the front taper roller bearing. SST 09316-12010, 09316-60011 (09316-00011)
13. INSTALL FRONT DRIVE GEAR PIECE Using SST and a press, install the front drive gear piece. SST 09316-12010, 09316-60011 (09316-00011)
14. INSTALL SNAP RING Select a snap ring that will allow the minimum axial play. Using a snap ring expander, install a new snap ring.
15. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE (See «DISASSEMBLY»(ref-209812-S01392368812005121100000) )

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1. REMOVE DRIVE CLUTCH HUB Using a snap ring expander, remove the snap ring. Using SST, remove the drive clutch hub. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04020, 09955-04021, 09957-04010, 09958-04011)
2. REMOVE FRONT OUTPUT SHAFT Using a plastic hammer, drive out the front output shaft.
3. REMOVE DUST DEFLECTOR Using SST, remove the dust deflector. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011) Using a screwdriver and hammer, tap the dust deflector and remove it from the extension housing.
4. REMOVE OIL SEAL Using a screwdriver, pry out the oil seal from the front extension housing.
5. REMOVE BALL BEARING Using a screwdriver, remove the snap ring. Using SST and a press, remove the ball bearing. SST 09316-60011 (09316-00011, 09316-00071)

HINT

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

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1. INSTALL DUST DEFLECTOR Using a plastic hammer, install a new dust deflector to the front extension housing. Using SST and a press, install a new dust deflector to the front output shaft. SST 09316-20011, 09316-60011 (09316-00011)
2. INSTALL BALL BEARING Using SST and a press, install the ball bearing to the front extension housing. SST 09316-60011 (09316-00011, 09316-00031) Select a snap ring that will allow the minimum axial play. Using a screwdriver, install a new snap ring.
3. INSTALL OIL SEAL Apply MP grease to the lip of a new oil seal. Using SST and a hammer, drive in a new oil seal to the front extension housing. SST 09316-60011 (09316-00011, 09316-00061)
4. INSTALL FRONT OUTPUT SHAFT AND DRIVE CLUTCH HUB Using SST and a press, install the front output shaft and drive clutch hub. SST 09316-20011, 09316-60011 (09316-00011, 09316-00041, 09316-00071) Select a snap ring that will allow the minimum axial play. Using a snap ring expander, install a new snap ring.

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1. REMOVE OIL PUMP DRIVE SHAFT
2. REMOVE OIL PUMP COVER Using a torx socket wrench (T30), remove the 3 screws. Install the 2 suitable bolts to the pump cover. Remove the pump cover from the rear extension housing.
3. REMOVE DRIVE ROTOR FROM DRIVEN ROTOR
4. REMOVE DRIVEN ROTOR FROM REAR EXTENSION HOUSING
5. REMOVE SCREW PLUG, SPRING, BALL AND VALVE SEAT Using a hexagon wrench, remove the screw plug. Using a magnetic finger, remove the spring, ball and valve seat from the rear extension housing.
6. REMOVE OIL PUMP PLATE Remove the 3 bolts and oil pump plate.
7. REMOVE SPEED SENSOR DRIVE GEAR Using a snap ring expander, remove the snap ring. Remove the speed sensor drive gear.
8. REMOVE REAR OUTPUT SHAFT Using a snap ring expander, remove the snap ring. Using SST and a hammer, remove the rear output shaft. SST 09325-12010 Remove the 2 seal rings from the rear output shaft.
9. REMOVE DUST DEFLECTOR Using a screwdriver and hammer, remove the rear extension housing dust deflector. Using a screwdriver and hammer, remove the rear output shaft dust deflector.
10. REMOVE OIL SEAL Using a screwdriver, pry out the oil seal from the rear extension housing.
11. REMOVE BALL BEARING Using a screwdriver, remove the snap ring. Using SST and a press, remove the ball bearing from the rear extension housing. SST 09316-60011 (09316-00011,09316-00021)

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1. INSPECT DRIVEN ROTOR BODY CLEARANCE Install the drive rotor and driven rotor to the rear extension housing. Using a feeler gauge, measure the body clearance between the drive rotor and extension housing. Standard clearance: 0.08 - 0.17 mm (0.0031 - 0.0067 in.) Maximum clearance: 0.17 mm (0.0067 in.) If the body clearance exceeds the maximum, replace the drive rotor and driven rotor.
2. INSPECT DRIVEN ROTOR TIP CLEARANCE Using a feeler gauge, measure the tip clearance between the drive rotor and driven rotor. Standard clearance: 0.05 - 0.15 mm (0.0020 - 0.0059 in.) Maximum clearance: 0.15 mm (0.0059 in.) If the tip clearance exceeds the maximum, replace the drive rotor and driven rotor.
3. INSPECT OIL PUMP SIDE CLEARANCE Using a steel straight edge and feeler gauge, measure the side clearance of oil pump. Standard clearance: 0.03 - 0.10 mm (0.0012 - 0.0039 in.) Maximum clearance: 0.10 mm (0.0039 in.) If the side clearance exceeds the maximum, replace the drive rotor and driven rotor.

HINT

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

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1. INSTALL BALL BEARING Using SST and a press, install the ball bearing. SST 09316-60011 (09316-00011, 09316-00031) Select a snap ring that will allow the minimum axial play. Using a screwdriver, install a new snap ring.
2. INSTALL DUST DEFLECTOR Using SST and a hammer, install a new rear extension housing dust deflector. SST 09316-60011 (09316-00011; 09316-00041) Using SST and a press, install a new rear output shaft dust deflector. SST 09316-20011,09316-60011 (09316-00011)
3. INSTALL OIL SEAL Apply MP grease to the lip of a new oil seal. Using SST and a hammer, drive in the oil seal. SST 09316-60011 (09316-00011, 09316-00031)
4. INSTALL REAR OUTPUT SHAFT Using SST and a press, install the rear output shaft. SST 09316-20011, 09316-60011 (09316-00011, 09316-00031) Install the 2 seal rings to the rear output shaft. Select a snap ring that will allow the minimum axial play. Using a snap ring expander, install a new snap ring.
5. INSTALL SPEED SENSOR DRIVE GEAR Install the speed sensor drive gear. Using a snap ring expander, install the snap ring.
6. INSTALL OIL PUMP PLATE Install the oil pump plate. Install and torque the 3 bolts. Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf)
7. INSTALL VALVE SEAT, BALL, SPRING AND SCREW PLUG Apply gear oil to the ball. Install the valve seat, ball and spring. Apply liquid sealer to the screw plug threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a hexagon wrench, install and torque the screw plug. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)
8. INSTALL DRIVEN ROTOR Apply gear oil to the driven rotor. Install the driven rotor.
9. INSTALL DRIVE ROTOR Apply gear oil to the drive rotor. Install the drive rotor. HINT: Align the alignment marks.
10. INSTALL OIL PUMP COVER Install the oil pump cover. Using a torx socket wrench (T30), install and torque the 3 screws. Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) NOTE: Align the oil hole of the rear extension housing and oil groove end of the oil pump cover.
11. INSTALL OIL PUMP DRIVE SHAFT

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1. INSPECT SWITCH POSITION Start the engine, and shift the transfer shift lever to the "H"position. Check that the center diff. indicator light comes on when the switch is in "ON"position. Check that the light goes off when the switch is in "OFF"position.
2. INSPECT SHIFT LEVER POSITION Start the engine, and turn the center diff. lock switch to OFF. Check that the center diff. indicator light comes on when the transfer shift lever is shifted to the "L"position. Check that the light goes off when the lever is shifted to the "N"or "H"position.
3. INSPECT CENTER DIFF. LOCK CONTROL RELAY Check that continuity exists between each terminal (Scheme 166) If no continuity exists, check that continuity exists when changing the position of (+) probe for the position of negative (-) probe of tester. Apply battery positive voltage between each terminal and check that continuity exists between each terminal (Scheme 167) If continuity is not as specified, replace the relay.
4. INSPECT ACTUATOR OPERATION Raise up the front wheels, place the stopper under the rear wheels to block them, and pull up the parking brake. Disconnect the connector of the actuator and connect it to the relay using wire. Check that the front propeller shaft can be rotated by hand. HINT: When inspecting the operation described above, use a heater main relay. NOTE: Connect the terminals being careful not to touch the neighboring terminals or metallic parts of relay housing.
5. INSPECT MOTOR ACTUATOR (MOTOR) Remove the motor actuator (See «DISASSEMBLY»(ref-209812-S04036258622005121100000) ). Measure the resistance between the terminals 1 and 5. Standard resistance: 0.3 - 100 ohm Measure the resistance between the terminals 1 or 5 and body ground. Standard resistance: More than 0.5 Mohm If the resistance value is not as specified, replace the motor actuator.
6. INSPECT CENTER DIFF. LOCK SWITCH CONTINUITY Remove the center diff. lock switch (See «DISASSEMBLY»(ref-215765-S39520878232006081800000) ). Inspect the continuity between each terminal.
7. INSPECT TRANSFER INDICATOR SWITCH CONTINUITY Remove the 3 transfer indicator switches (See «DISASSEMBLY»(ref-209812-S04036258622005121100000) ). Check that continuity exists between terminals 1 and 2 when pushing the ball at the tip of the switch.