Transfer (Service Information): Overview Lexus LX J200

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1. CHECK TRANSFER OIL LEVEL Remove the filler plug and gasket. Check that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler plug hole. If the result is not as specified, add transfer oil. Oil Grade GL-5 Viscosity SAE 75W-90 Standard Capacity 1.4 to 1.5 liters (1.47 to 1.59 US qts, 1.23 to 1.32 Imp. qts) NOTE: Too much or too little oil will lead to transfer problems. When the oil level is too low, check for oil leaks. Install a new gasket to the filler plug and then install the plug. Torque: 37 N*m ( 377 kgf*cm, 27 ft.*lbf)
2. ADD TRANSFER OIL Remove the filler plug and gasket. Add oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler plug hole. NOTE: Add oil slowly. Add oil a little at a time, waiting several minutes between each addition of oil. Wait approximately 5 minutes and check that the oil level has not changed. Install a new gasket to the filler plug and then install the plug. Torque: 37 N*m ( 377 kgf*cm, 27 ft.*lbf)

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1. DRAIN TRANSFER OIL Remove the 2 bolts and transfer dynamic damper. Remove the 4 bolts and transfer heat insulator. Remove the 7 bolts and lower transfer case protector. Remove the filler plug and gasket. Remove the drain plug and gasket, and drain the transfer oil.
2. ADD TRANSFER OIL Install a new gasket to the drain plug and then install the plug. Torque: 37 N*m ( 377 kgf*cm, 27 ft.*lbf) Add oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler plug hole. NOTE: Add oil slowly. Add oil a little at a time, waiting several minutes between each addition of oil. Wait approximately 5 minutes and check that the oil level has not changed. Install a new gasket to the filler plug and then install the plug. Torque: 37 N*m ( 377 kgf*cm, 27 ft.*lbf) Install the lower transfer case protector with the 7 bolts. Torque: 14 N*m ( 139 kgf*cm, 10 ft.*lbf) Install the transfer heat insulator with the 4 bolts. Torque: 30 N*m ( 306 kgf*cm, 22 ft.*lbf) Install the transfer dynamic damper with the 2 bolts. Torque: 12 N*m ( 122 kgf*cm, 9 ft.*lbf)

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1. DRAIN TRANSFER OIL See step 1
2. REMOVE FRONT PROPELLER SHAFT ASSEMBLY Remove the front propeller shaft. Refer to «REMOVAL»(ref-385192-S03577967122011021400000) .
3. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See step 6
4. REMOVE TRANSFER CASE FRONT OIL SEAL Using SST, tap out the oil seal. SST: 09308-00010 NOTE: Be careful not to damage the oil seal and front transfer case contact surface.
5. INSTALL TRANSFER CASE FRONT OIL SEAL Apply transfer oil to the spline of the driven sprocket. Using SST and a hammer, tap in a new oil seal until its surface is 1 to 1.5 mm (0.0394 to 0.0590 in.) from the case upper surface. SST: 09649-17010 SST: 09950-70010 09951-07150
6. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See step 31
7. INSTALL FRONT PROPELLER SHAFT ASSEMBLY Install the front propeller shaft. Refer to «INSTALLATION»(ref-385192-S18131084942011021400000) .
8. ADD TRANSFER OIL See step 2
9. CHECK FOR TRANSFER OIL LEAK

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1. REMOVE PROPELLER SHAFT ASSEMBLY Remove the propeller shaft assembly. Refer to «REMOVAL»(ref-385192-S37750235742011021400000) .
2. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See step 8
3. REMOVE TRANSFER CASE REAR OIL SEAL Using SST, tap out the oil seal. SST: 09308-00010 NOTE: Be careful not to damage the oil seal and rear transfer case contact surface.
4. INSTALL TRANSFER CASE REAR OIL SEAL Apply transfer oil to the spline of the output shaft. Using SST and a hammer, tap in a new oil seal until its surface is flush with the housing upper surface. SST: 09649-17010 SST: 09950-70010 09951-07150
5. INSTALL REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY See step 29
6. INSTALL PROPELLER SHAFT ASSEMBLY Install the propeller shaft assembly. Refer to «INSTALLATION»(ref-385192-S30819848782011021400000) .

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1. DRAIN TRANSFER OIL See step 1
2. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER ASSEMBLY Remove the automatic transmission with transfer assembly. Refer to «REMOVAL»(ref-385187-S02660299292011021400000) .
3. REMOVE TRANSFER ASSEMBLY Remove the 8 transfer adaptor rear mounting bolts. Pull the transfer straight up and remove it from the transmission. NOTE: Take care not to damage the adaptor oil seal with the transfer input shaft spline.

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1. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY Remove the bolt and bracket.
2. REMOVE TRANSFER OIL PUMP PLATE Remove the 4 bolts, oil pump plate and oil pump driven rotor. NOTE: Do not drop the oil pump driven rotor. Remove the O-ring from the oil pump plate. Remove the transfer oil seal ring from the input shaft. Remove the oil pump drive rotor from the input shaft.
3. REMOVE TRANSFER CASE STRAIGHT PIN Remove the 2 straight pins. NOTE: Do not drop the straight pins.
4. REMOVE TRANSFER CASE PLUG Using a 10 mm hexagon wrench, remove the case plug, compression spring, ball and relief valve seat.
5. REMOVE TRANSFER OIL PUMP PLATE OIL SEAL Using a screwdriver, pry out the oil seal from the oil pump plate. NOTE: Be careful not to damage the oil seal and oil pump plate contact surfaces. HINT: Tape the screwdriver tip before use.
6. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY Using SST and a hammer, release the staked part of the nut. SST: 09930-00010 09931-00010 09931-00020 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 nut when removing it. Do not damage the threads of the transfer driven sprocket. Using SST to hold the companion flange, remove the lock nut. SST: 09330-00021 Using SST, remove the companion flange. SST: 09950-40011 09951-04020 09952-04010 09953-04030 09954-04010 09955-04051 09957-04010 09958-04011 Remove the O-ring from the companion flange.
7. REMOVE TRANSFER CASE FRONT OIL SEAL See step 4
8. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY Using SST and a hammer, release the staked part of the nut. SST: 09930-00010 09931-00010 09931-00020 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 nut when removing it. Do not damage the threads of the rear transfer output shaft. Using SST to hold the companion flange, remove the lock nut. SST: 09330-00021 Using SST, remove the companion flange. SST: 09950-40011 09951-04020 09952-04010 09953-04030 09954-04010 09955-04051 09957-04010 09958-04011 Remove the O-ring from the companion flange.
9. REMOVE TRANSFER CASE REAR OIL SEAL See step 3
10. REMOVE NO. 1 TRANSFER CASE PLUG Remove the plug, compression spring and pin.
11. REMOVE TRANSFER CASE PLUG Using a 6 mm hexagon wrench, remove the plug.
12. REMOVE REAR TRANSFER CASE ASSEMBLY Remove the 14 bolts. Remove the rear transfer case. HINT: If necessary, tap the rear transfer case with a plastic-faced hammer to remove it.
13. REMOVE FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING Remove the needle roller bearing and spacer from the output shaft.
14. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK Using 2 screwdrivers and a hammer, tap off the 4 shift fork shaft snap rings. Remove the bolt. Then remove the No. 2 gear shift fork together with the high and low clutch sleeve from the shift actuator.
15. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY Remove the No. 1 gear shift fork bolt. Remove the 3 bolts. Remove the shift actuator, No. 1 gear shift fork, washer, and straight pin from the rear transfer case. NOTE: Take care not to drop the No. 1 gear shift fork, washer, and straight pin. Remove the O-ring from the shift actuator.
16. REMOVE REAR TRANSFER OUTPUT SHAFT ASSEMBLY Using a snap ring expander, expand the snap ring as shown in the illustration. Using a plastic-faced hammer, carefully tap the rear transfer case, and remove the output shaft together with the drive chain and driven sprocket. Remove the output shaft and driven sprocket from the drive chain. NOTE: Do not drop the output shaft washers. Using a snap ring expander, remove the snap ring from the rear transfer case.
17. REMOVE FRONT DRIVE CLUTCH SLEEVE Remove the clutch sleeve from the output shaft.
18. REMOVE SIDE GEAR SHAFT HOLDER BEARING Using a screwdriver, remove the snap ring. Using SST, remove the bearing. SST: 09308-00010
19. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY Remove the 3 bolts and oil separator. Remove the O-ring from the oil separator.
20. REMOVE TRANSFER CASE MAGNET Remove the magnet from the oil separator.
21. REMOVE TRANSFER INPUT SHAFT ASSEMBLY Using a 14 mm hexagon wrench, remove the 2 case plugs from the front transfer case. Using a snap ring expander, expand the snap ring as shown in the illustration. Then remove the input shaft from the front transfer case.
22. REMOVE TRANSFER LOW PLANETARY RING GEAR Using a screwdriver, remove the snap ring. Then remove the low planetary ring gear from the front transfer case. Using a snap ring expander, remove the snap ring from the front transfer case.
23. REMOVE TRANSFER DRIVEN SPROCKET BEARING Using a screwdriver, remove the snap ring. Then remove the bearing from the front transfer case.
24. REMOVE NO. 1 SYNCHRONIZER RING Remove the synchronizer ring from the input shaft.
25. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING Remove the seal ring from the input shaft.
26. REMOVE TRANSFER INPUT SHAFT BEARING Using a snap ring expander, remove the snap ring. Using SST and a press, press out the bearing. SST: 09555-55010 SST: 09950-60010 09951-00490 SST: 09950-70010 09951-07100 NOTE: Be careful not to drop or damage the input shaft, low planetary gear and low planetary gear bearings. HINT: When the bearing is removed, the input shaft, low planetary gear, and 2 low planetary gear bearings will come off.
27. REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH Using SST, remove the bush. SST: 09387-00041 09387-01021 09387-01030 09387-01040
28. REMOVE TRANSFER INPUT SHAFT PLUG Using SST and a hammer, tap out the input shaft plug. SST: 09950-70010 09951-07150 SST: 09950-60010 09951-00300
29. REMOVE TRANSFER OUTPUT SHAFT WASHER Remove the 2 output shaft washers from the output shaft.
30. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER Using 2 screwdrivers and a hammer, tap off the snap ring. Remove the output shaft spacer from the output shaft. Remove the seal ring from the output shaft spacer. Remove the straight pin from the output shaft.
31. REMOVE CENTER DIFFERENTIAL CASE Remove the center differential case from the output shaft. Using a snap ring expander, remove the snap ring. Remove the synchromesh shifting key spring and No. 2 synchromesh shifting keys from the center differential case. Using SST, remove the needle roller bearing. SST: 09308-00010 Using SST, remove the needle roller bearing. SST: 09387-00041 09387-01021 09387-01030 09387-01040
32. REMOVE TRANSFER OUTPUT SHAFT SPACER Using 2 screwdrivers and a hammer, tap off the snap ring. Remove the output shaft spacer from the output shaft. Remove the straight pin from the output shaft.
33. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY Remove the drive sprocket from the output shaft.
34. REMOVE TRANSFER DRIVE SPROCKET BEARING Remove the bearing from the output shaft.
35. REMOVE REAR TRANSFER OUTPUT SHAFT Using SST and a press, press out the bearing. SST: 09527-10011 NOTE: Be careful not to drop or damage the output shaft. Remove the needle roller bearing from the output shaft.

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1. INSPECT TRANSFER INPUT SHAFT Using a micrometer, measure the diameter of the input shaft journal surface. Minimum Diameter 68 mm (2.68 in.) If the diameter is less than the minimum, replace the input shaft. Using a dial indicator, measure the inside diameter of the input shaft bush. Maximum Inside Diameter 46 mm (1.81 in.) If the inside diameter is more than the maximum, replace the input shaft.
2. INSPECT TRANSFER LOW PLANETARY GEAR ASSEMBLY Using a feeler gauge, measure the thrust clearance of the pinion gear. Standard Clearance 0.11 to 0.85 mm (0.00434 to 0.0334 in.) Maximum Clearance 0.85 mm (0.0334 in.) If the clearance is more than the maximum, replace the low planetary gear assembly. Using a dial indicator, measure the radial clearance of the pinion gear. Standard Clearance 0.01 to 0.04 mm (0.000434 to 0.00150 in.) Maximum Clearance 0.04 mm (0.00150 in.) If the clearance is more than the maximum, replace the low planetary gear assembly.
3. INSPECT REAR TRANSFER OUTPUT SHAFT Using a micrometer, measure the diameter of the output shaft journals. Minimum Diameter Journal Specified Condition A 38 mm (1.50 in.) B 42 mm (1.65 in.) C 49 mm (1.93 in.) If the diameter is less than the minimum, replace the output shaft.
4. INSPECT NO. 1 TRANSFER GEAR SHIFT FORK AND FRONT DRIVE CLUTCH SLEEVE Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork. Maximum Clearance 0.8 mm (0.0315 in.) If the clearance is more than the maximum, replace the clutch sleeve or shift fork.
5. INSPECT AND ADJUST NO. 2 TRANSFER GEAR SHIFT FORK AND HIGH AND LOW CLUTCH SLEEVE Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork. Maximum Clearance 3.15 mm (0.124 in.) If the clearance is more than the maximum, replace the clutch sleeve or shift fork.
6. INSPECT NO. 1 SYNCHRONIZER RING Apply gear oil to the cone of the input shaft, and check that it does not turn in both directions while pushing the No. 1 synchronizer ring. If it can turn, replace the No. 1 synchronizer ring. Push the No. 1 synchronizer ring to the cone of the input shaft. Measure the clearance between the No. 1 synchronizer ring and input shaft. Standard Clearance 0.86 to 1.54 mm (0.0339 to 0.0606 in.) Minimum Clearance 0.86 mm (0.0339 in.) If the clearance is less than the minimum, replace the No. 1 synchronizer ring with a new one.