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Transfer Case (Service Information): Overhaul Lexus RX III

Transfer Case 7 illustrations ~4374 words

DISASSEMBLY

  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT Remove the 4 transfer and transaxle setting stud bolts.
  2. REMOVE NO. 2 TRANSFER CASE PLUG Remove the No. 2 transfer case plug. Remove the gasket from the No. 2 transfer case plug.
  3. REMOVE NO. 1 TRANSFER CASE PLUG Remove the No. 1 transfer case plug. Remove the gasket from the No. 1 transfer case plug.
  4. REMOVE TRANSFER DRAIN PLUG Remove the transfer drain plug. Remove the gasket from the transfer drain plug.
  5. REMOVE TRANSFER CASE BREATHER PLUG Using a screwdriver, remove the transfer case breather plug.
  6. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY Remove the 8 bolts. Using a brass bar and a hammer, remove the transfer case cover sub-assembly from the transfer case. NOTE: Place the brass bar on the rib protruding from the case.
  7. REMOVE BREATHER OIL DEFLECTOR Remove the bolt and breather oil deflector.
  8. REMOVE TRANSFER DYNAMIC DAMPER Remove the 3 bolts and transfer dynamic damper from the transfer extension housing sub-assembly.
  9. REMOVE TRANSFER CASE STRAIGHT PIN Remove the 4 transfer case straight pins from the transfer case.
  10. SECURE TRANSFER ASSEMBLY Attach the transfer assembly to the overhaul attachment.
  11. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.
  12. REMOVE TRANSFER CASE REAR OIL SEAL Using SST, remove the transfer case rear oil seal from the transfer extension housing sub-assembly. SST: 09308-00010 NOTE: Be careful not to damage the oil seal contact surface or the inside surface of the oil seal.
  13. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY Remove the 4 bolts. Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case.
  14. INSPECT PRELOAD See step 1
  15. INSPECT RING GEAR BACKLASH See step 2
  16. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION See step 3
  17. REMOVE TRANSFER CASE FRONT OIL SEAL Using SST, remove the transfer case front oil seal from the transfer case. SST: 09308-00010 NOTE: Do not damage the oil seal contact surface on the case.
  18. REMOVE TRANSFER CASE FRONT OIL SEAL (for RH Side) Using SST, remove the transfer case front oil seal from the transfer case. SST: 09308-00010 NOTE: Do not damage the oil seal contact surface on the case.
  19. REMOVE BEARING CAP Remove the 2 bolts and bearing cap.
  20. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer. TEXT IN ILLUSTRATION *1 Screwdriver *2 Piece of Cloth *3 Spacer SST: 09504-22011 NOTE: Do not damage the transfer case.
  21. REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER
  22. REMOVE TRANSFER RING GEAR MOUNTING CASE Remove the transfer ring gear mounting case from the transfer case.
  23. REMOVE DRIVEN PINION Using SST and a hammer, unstake the gear nut. SST: 09930-00010 HINT: Use SST with the flat side facing outward. Do not machine the tip of SST with a grinder, etc. Using SST, remove the gear nut. TEXT IN ILLUSTRATION *1 Turn *2 Hold SST: 09326-20011 SST: 09556-16030 Using a press, press out the driven pinion, transfer driven pinion rear bearing (inner race) and transfer pinion bearing spacer. NOTE: Place a piece of cloth under the transfer case to prevent the driven pinion from dropping out of the bearing. Use wooden blocks or similar objects under the case to keep it level.
  24. REMOVE TRANSFER DRIVEN PINION FRONT BEARING Using SST and a press, press out the transfer driven pinion front bearing (inner race). SST: 09950-00020 Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the driven pinion front bearing (outer race) to remove it from the case.
  25. REMOVE TRANSFER OUTPUT SHAFT WASHER Remove the transfer output shaft washer.
  26. REMOVE RING GEAR MOUNTING CASE BEARING Remove the ring gear mounting case bearing (outer race) RH from the transfer ring gear mounting case. Using SST, remove the ring gear mounting case bearing (inner race) RH from the transfer ring gear mounting case. TEXT IN ILLUSTRATION *1 Turn *2 Hold SST: 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09955-04061 09957-04010 09958-04011 SST: 09950-60010 09951-00440 NOTE: Use SST (09953-04020) after applying grease to its threads and tip. Using SST, remove the ring gear mounting (inner race) LH from the transfer ring gear mounting case. TEXT IN ILLUSTRATION *1 Turn *2 Hold SST: 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09955-04061 09957-04010 09958-04011 SST: 09950-60010 09951-00400 NOTE: Use SST (09953-04020) after applying grease to its threads and tip. Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the ring gear mounting case bearing (outer race) LH to remove it from the transfer case. Remove the ring gear mounting case plate washer.
  27. INSPECT RUNOUT OF RING GEAR See step 4
  28. REMOVE RING GEAR Put matchmarks on the transfer ring gear mounting case and ring gear. TEXT IN ILLUSTRATION *1 Matchmark Remove the 12 bolts. Using a plastic hammer, tap on the ring gear to separate it from the transfer ring gear mounting case. NOTE: Do not damage the ring gear teeth.
  29. INSPECT TRANSFER RING GEAR MOUNTING CASE See step 5
  30. REMOVE TRANSFER DRIVEN PINION REAR BEARING Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the driven pinion rear bearing (outer race) to remove it from the transfer case.

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Scheme 105: INSPECTION
Scheme 105: INSPECTION

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Scheme 110
Scheme 110
  1. INSPECT PRELOAD Using SST and a torque wrench, measure the preload of the backlash between the driven pinion and ring gear. SST: 09326-20011 Preload (at Starting) Item Preload without SST 0.5 to 0.9 N*m (5 to 9 kgf*cm, 4 to 8 in.*lbf) with SST 0.3 to 0.6 N*m (3 to 6 kgf*cm, 3 to 5 in.*lbf) NOTE: The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.). The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.). Refer to «PRECAUTION»(ref-400649-S21890762562011051800000) . The "with SST" torque value is effective when SST is parallel to the torque wrench. Using SST and a torque wrench, measure the total preload. SST: 09326-20011 Preload (at Starting) Item Preload without SST 0.4 to 0.5 N*m (4 to 5 kgf*cm, 3 to 4 in.*lbf) + driven pinion preload with SST 0.25 to 0.38 N*m (2.6 to 3.8 kgf*cm, 2.3 to 3.3 in.*lbf) + driven pinion preload NOTE: The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.). The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.). Refer to «PRECAUTION»(ref-400649-S21890762562011051800000) . The "with SST" torque value is effective when SST is parallel to the torque wrench.
  2. INSPECT RING GEAR BACKLASH Using a dial indicator, check the backlash of the ring gear. Backlash 0.14 to 0.25 mm (0.00551 to 0.00984 in.) If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. NOTE: Check at least 3 positions on the circumference of the ring gear.
  3. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue. Rotate the ring gear 10 times more. Rotate the ring gear to inspect the tooth contact pattern. If the tooth contact pattern is not correct, select a new transfer output shaft washer that is thicker or thinner as necessary and recheck.
  4. INSPECT RING GEAR RUNOUT Place the transfer ring gear mounting case on the V-blocks. Using a dial indicator, check the runout of the ring gear. Maximum runout 0.06 mm (0.00236 in.)
  5. INSPECT TRANSFER RING GEAR MOUNTING CASE RUNOUT Place the transfer ring gear mounting case on the V-blocks. Using a dial indicator, check the runout of the ring gear mounting case. Maximum runout 0.04 mm (0.00157 in.)

REASSEMBLY

  1. INSTALL TRANSFER DRIVEN PINION REAR BEARING Using SST and a press, press the driven pinion rear bearing (outer race) into the case. SST: 09950-60010 09951-00620 SST: 09950-70010 09951-07150 NOTE: Keep the transfer case horizontal using wooden blocks, etc. Apply gear oil to the driven pinion rear bearing (outer race).
  2. INSTALL TRANSFER OUTPUT SHAFT WASHER Install the transfer output shaft washer to the transfer case. HINT: Install the same washer as the one removed. Apply gear oil to the transfer output shaft washer.
  3. INSTALL TRANSFER DRIVEN PINION FRONT BEARING Apply gear oil to the inner surface of the transfer case. TEXT IN ILLUSTRATION *1 Turn *2 Hold Using SST, install the transfer driven pinion front bearing (outer race) to the transfer case. SST: 09950-60010 09951-00610 09951-00620 09951-00650 SST: 09950-60020 09951-00680 Using SST and a press, press the driven pinion front bearing (inner race) into the driven pinion. SST: 09506-30012
  4. INSTALL DRIVEN PINION Install the driven pinion to the transfer case. Install a new transfer pinion bearing spacer and driven pinion rear bearing (inner race) to the driven pinion. HINT: Install the pinion bearing spacer with the larger inner diameter facing forward as shown in the illustration. Using SST, install a new gear nut. SST: 09326-20011 SST: 09556-16030 Reference without SST Torque: 270 to 420 N*m (2754 to 4282 kgf*cm, 199 to 308 ft.*lbf) Reference with SST Torque: 255 to 396 N*m (2601 to 4038 kgf*cm, 188 to 291 ft.*lbf) NOTE: The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.). The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 840 mm (2.8 ft.). Refer to «PRECAUTION»(ref-400649-S04310564762011051800000) . The "with SST" torque value is effective when SST is parallel to the torque wrench. Do not stake the nut until the final preload, tooth contact and backlash adjustments are completed.
  5. ADJUST DRIVEN PINION PRELOAD Using SST and a torque wrench, measure the driven pinion preload. SST: 09326-20011 Preload (at Starting) Item Preload New bearing (without SST) 0.7 to 1.4 N*m (7 to 15 kgf*cm, 6 to 13 in.*lbf) New bearing (with SST) 0.5 to 1.0 N*m (5 to 10 kgf*cm, 5 to 9 in.*lbf) Reused bearing (without SST) 0.5 to 0.9 N*m (5 to 9 kgf*cm, 4 to 8 in.*lbf) Reused bearing (with SST) 0.3 to 0.6 N*m (3 to 6 kgf*cm, 3 to 6 in.*lbf) NOTE: The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.). The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.). Refer to «PRECAUTION»(ref-400649-S04310564762011051800000) . The "with SST" torque value is effective when SST is parallel to the torque wrench. If the preload is more than the specification, replace the pinion bearing spacer with a new one. If the preload is not sufficient, adjust the driven pinion by tightening the lock nut 5° to 10° and measuring the preload until the preload is within the specification. Even if the tightening torque of the gear nut exceeds the specified torque, if the preload is insufficient, loosen the gear nut once and apply rust preventive oil or hypoid gear oil to the gear nut and to the screw or bearing surface of the driven pinion. Then perform the procedure again. If the tightening torque is less than the specified torque, replace the pinon bearing spacer with a new one and adjust it. Do not loosen the gear nut to reduce the preload.
  6. INSTALL RING GEAR Clean the contact surface of the ring gear and transfer ring gear mounting case. Heat the ring gear in boiling water. Carefully remove the ring gear from the boiling water. After the moisture on the ring gear has completely evaporated, quickly align the matchmarks, set the ring gear onto the transfer ring gear mounting case. TEXT IN ILLUSTRATION *1 Matchmark Apply adhesive to the 12 bolts. Sealant Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the 12 bolts. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) NOTE: Tighten the bolts evenly in a diagonal pattern using several steps. Tighten the bolts after the ring gear has cooled down sufficiently. In order to ensure proper sealing of the bolts, apply adhesive to the bolts and install them within 10 minutes of adhesive application.
  7. INSTALL RING GEAR MOUNTING CASE BEARING Using SST and a press, press the ring gear mounting case bearing (inner race) RH into the transfer ring gear mounting case. SST: 09950-60010 09951-00420 Install the ring gear mounting case bearing (outer race) RH to the transfer ring gear mounting case. Apply gear oil to the ring gear mounting case bearing RH. Using SST and a press, press the ring gear mounting case bearing (inner race) LH into the transfer ring gear mounting case. SST: 09223-00010 SST: 09726-40010 Install the ring gear mounting case plate washer to the case. HINT: Use a new washer with the same thickness as the one removed when installing the bearing. Using SST and a press, press the ring gear mounting case bearing (outer race) LH into the transfer case. SST: 09950-60010 09951-00620 SST: 09950-70010 09951-07200 Apply gear oil to the ring gear mounting case bearing.
  8. INSTALL TRANSFER RING GEAR MOUNTING CASE Apply gear oil to the transfer ring gear mounting case. Install the transfer ring gear mounting case to the transfer case.
  9. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER Align the cutout on the No. 1 transfer output shaft spacer with the transfer case hole to install it as shown in the illustration.
  10. INSTALL NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER Using a brass bar and a hammer, install the No. 2 transfer ring gear mounting case washer. HINT: Use the No. 2 washer with the same thickness as the one removed.
  11. INSTALL BEARING CAP Install the bearing cap with the 2 bolts. Torque: 63 N*m (644 kgf*cm, 47 ft.*lbf)
  12. INSPECT RING GEAR BACKLASH Set a dial indicator perpendicular to a ring gear tooth tip. Secure the driven pinion in place and move the ring gear back and forth to measure the backlash. Backlash 0.14 to 0.25 mm (0.00551 to 0.00984 in.) NOTE: Check at least 3 positions on the circumference of the ring gear. If the backlash is outside the specified range, select a ring gear mounting case bearing LH side washer from the table below and install it to meet the specified range. TEXT IN ILLUSTRATION *1 Ring Gear Mounting Case Plate Washer WASHER THICKNESS Mark Thickness mm (in.) Mark Thickness mm (in.) 5Q 1.95 (0.0768) 7N 2.67 (0.105) 5R 1.97 (0.0776) 7P 2.69 (0.10591) 5S 1.99 (0.0783) 7Q 2.71 (0.106) 5T 2.01 (0.0791) 7R 2.73 (0.107) 5U 2.03 (0.0799) 7S 2.75 (0.108) 5V 2.05 (0.0807) 7T 2.77 (0.10905) 5W 2.07 (0.0815) 7U 2.79 (0.10984) 5X 2.09 (0.0823) 7V 2.81 (0.11063) 5Y 2.11 (0.0831) 7W 2.83 (0.11142) 5Z 2.13 (0.0839) 7X 2.85 (0.11220) 6F 2.15 (0.0846) 7Y 2.87 (0.11299) 6G 2.17 (0.0854) 7Z 2.89 (0.11378) 6H 2.19 (0.0862) 8F 2.91 (0.11457) 6J 2.21 (0.0870) 8G 2.93 (0.115) 6K 2.23 (0.0878) 8H 2.95 (0.11614) 6L 2.25 (0.0886) 8J 2.97 (0.11693) 6M 2.27 (0.0894) 8K 2.99 (0.11771) 6N 2.29 (0.0902) 8L 3.01 (0.11850) 6P 2.31 (0.0909) 8M 3.03 (0.11929) 6Q 2.33 (0.0917) 8N 3.05 (0.12008) 6R 2.35 (0.0925) 8P 3.07 (0.12087) 6S 2.37 (0.0933) 8Q 3.09 (0.12165) 6T 2.39 (0.0941) 8R 3.11 (0.12244) 6U 2.41 (0.0949) 8S 3.13 (0.123) 6V 2.43 (0.0957) 8T 3.15 (0.12402) 6W 2.45 (0.0965) 8U 3.17 (0.12480) 6X 2.47 (0.0972) 8V 3.19 (0.12559) 6Y 2.49 (0.0980) 8W 3.21 (0.12638) 6Z 2.51 (0.0988) 8X 3.23 (0.12717) 7F 2.53 (0.0996) 8Y 3.25 (0.12795) 7G 2.55 (0.100) 8Z 3.27 (0.12874) 7H 2.57 (0.10118) 9D 3.29 (0.12953) 7J 2.59 (0.10197) 9E 3.31 (0.13031) 7K 2.61 (0.10276) 9F 3.33 (0.131) 7L 2.63 (0.10354) 9G 3.35 (0.132) 7M 2.65 (0.10433) 9H 3.37 (0.133)
  13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue. Rotate the ring gear 10 times or more. Rotate the ring gear to inspect the tooth contact pattern. If the tooth contact pattern is not correct, select a new transfer output shaft washer that is thicker or thinner as necessary and recheck. TEXT IN ILLUSTRATION *1 Transfer Output Shaft Washer WASHER THICKNESS Mark Thickness mm (in.) Mark Thickness mm (in.) ZA 2.00 (0.0787) KB 2.38 (0.0937) ZB 2.02 (0.0795) LA 2.40 (0.0945) ZC 2.04 (0.0803) LC 2.42 (0.0953) ZD 2.06 (0.0811) MB 2.44 (0.0961) ZE 2.08 (0.0819) NA 2.46 (0.0969) AA 2.10 (0.0827) NC 2.48 (0.0976) AC 2.12 (0.0835) PB 2.50 (0.0984) BB 2.14 (0.0843) QA 2.52 (0.0992) CA 2.16 (0.0850) QC 2.54 (0.100) CC 2.18 (0.0858) RA 2.56 (0.10079) DB 2.20 (0.0866) RB 2.58 (0.10157) EA 2.22 (0.0874) RC 2.60 (0.10236) EC 2.24 (0.0882) SA 2.62 (0.10315) FB 2.26 (0.0890) SB 2.64 (0.10394) GA 2.28 (0.0898) SC 2.66 (0.10472) GC 2.30 (0.0906) TA 2.68 (0.10551) HB 2.32 (0.0913) TB 2.70 (0.10630) JA 2.34 (0.0921) TC 2.72 (0.107) JC 2.36 (0.0929) - - NOTE: When the washer thickness is changed, readjust the backlash See step 2 .
  14. INSPECT AND ADJUST TOTAL PRELOAD Using SST and a torque wrench, measure the total preload. SST: 09326-20011 Total Preload (at Starting) Item Preload New bearing (without SST) 0.5 to 0.7 N*m (5 to 7 kgf*cm, 5 to 6 in.*lbf) + Driven pinion preload New bearing (with SST) 0.4 to 0.5 N*m (4 to 5 kgf*cm, 3 to 4 in.*lbf) + Driven pinion preload Reused bearing (without SST) 0.4 to 0.5 N*m (4 to 5 kgf*cm, 3 to 4 in.*lbf) + driven pinion preload Reused bearing (with SST) 0.25 to 0.38 N*m (2.6 to 3.8 kgf*cm, 2.3 to 3.3 in.*lbf) + driven pinion preload NOTE: The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.). The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.). Refer to «PRECAUTION»(ref-400649-S04310564762011051800000) . The "with SST" torque value is effective when SST is parallel to the torque wrench. Turn the driven pinion counterclockwise and clockwise several times. If the preload is outside the specified range, replace the No. 2 transfer ring gear mounting case washer with one that is thicker or thinner as necessary and recheck. TEXT IN ILLUSTRATION *1 No. 2 Transfer Ring Gear Mounting Case Washer WASHER THICKNESS Mark Thickness mm (in.) Mark Thickness mm (in.) G7 2.47 (0.0972) M7 3.47 (0.1366) G8 2.49 (0.0980) M8 3.49 (0.137) G9 2.51 (0.0988) M9 3.51 (0.138) H0 2.53 (0.0996) N0 3.53 (0.139) H1 2.55 (0.100) N1 3.55 (0.140) H2 2.57 (0.101) N2 3.57 (0.141) H3 2.59 (0.102) N3 3.59 (0.1413) H4 2.61 (0.103) N4 3.61 (0.142) H5 2.63 (0.104) N5 3.63 (0.143) H6 2.65 (0.1043) N6 3.65 (0.144) H7 2.67 (0.105) N7 3.67 (0.1444) H8 2.69 (0.106) N8 3.69 (0.145) H9 2.71 (0.107) N9 3.71 (0.146) J0 2.73 (0.1074) P0 3.73 (0.147) J1 2.75 (0.108) P1 3.75 (0.148) J2 2.77 (0.109) P2 3.77 (0.1484) J3 2.79 (0.110) P3 3.79 (0.149) J4 2.81 (0.1106) P4 3.81 (0.150) J5 2.83 (0.111) P5 3.83 (0.151) J6 2.85 (0.112) P6 3.85 (0.152) J7 2.87 (0.113) P7 3.87 (0.1523) J8 2.89 (0.114) P8 3.89 (0.153) J9 2.91 (0.115) P9 3.91 (0.154) K0 2.93 (0.1153) Q0 3.93 (0.155) K1 2.95 (0.116) Q1 3.95 (0.156) K2 2.97 (0.117) Q2 3.97 (0.1563) K3 2.99 (0.118) Q3 3.99 (0.157) K4 3.01 (0.119) Q4 4.01 (0.158) K5 3.03 (0.1193) Q5 4.03 (0.159) K6 3.05 (0.120) Q6 4.05 (0.160) K7 3.07 (0.121) Q7 4.07 (0.1602) K8 3.09 (0.122) Q8 4.09 (0.161) K9 3.11 (0.1224) Q9 4.11 (0.162) L0 3.13 (0.123) R0 4.13 (0.163) L1 3.15 (0.124) R1 4.15 (0.1634) L2 3.17 (0.125) R2 4.17 (0.164) L3 3.19 (0.126) R3 4.19 (0.165) L4 3.21 (0.1264) R4 4.21 (0.166) L5 3.23 (0.127) R5 4.23 (0.167) L6 3.25 (0.128) R6 4.25 (0.1673) L7 3.27 (0.129) R7 4.27 (0.168) L8 3.29 (0.130) R8 4.29 (0.169) L9 3.31 (0.1303) R9 4.31 (0.170) M0 3.33 (0.131) S0 4.33 (0.1705) M1 3.35 (0.132) S1 4.35 (0.171) M2 3.37 (0.133) S2 4.37 (0.172) M3 3.39 (0.1335) S3 4.39 (0.173) M4 3.41 (0.134) S4 4.14 (0.174) M5 3.43 (0.135) S5 4.43 (0.1744) M6 3.45 (0.136) S6 4.45 (0.175) Using a chisel and a hammer, stake the gear nut.
  15. INSTALL TRANSFER CASE FRONT OIL SEAL (for RH Side) Using SST and a hammer, drive a new transfer case front oil seal into the case until it reaches the position shown in the illustration. SST: 09950-60010 09951-00350 09951-00580 09952-06010 SST: 09950-70010 09951-07150 Drive in depth 33.5 to 34.5 mm (1.32 to 1.36 in.) NOTE: Make sure that the oil seal is not tilted. Apply a small amount of MP grease to the lip of the transfer case front oil seal.
  16. INSTALL TRANSFER CASE FRONT OIL SEAL Using SST and a hammer, drive a new transfer case front oil seal into the transfer case until it reaches the position shown in the illustration. SST: 09608-10010 SST: 09950-70010 09951-07150 Drive in depth 9.5 to 10.5 mm (0.374 to 0.413 in.) Apply a small amount of MP grease to the lip of the transfer case front oil seal.
  17. INSTALL TRANSFER CASE REAR OIL SEAL Using SST and a hammer, drive a new transfer case rear oil seal into the extension housing until it reaches the position shown in the illustration. SST: 09325-20010 Drive in depth 1.1 to 1.9 mm (0.0433 to 0.0748 in.) Apply a small amount of MP grease to the lip of the transfer case rear oil seal.
  18. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR Using SST and a press, press in the extension housing dust deflector until it contacts the installation surface as shown in the illustration. SST: 09950-60020 09951-00810 SST: 09950-70010 09951-07150
  19. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY Remove any FIPG material and be careful not to drop oil on the contact surfaces of the transfer extension housing sub-assembly and the transfer case. Degrease the surfaces with a non-residue solvent. Apply FIPG to the transfer extension housing sub-assembly. FIPG Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Install the transfer extension housing sub-assembly with the 4 bolts to the transfer case. Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) NOTE: Assemble the transfer extension housing sub-assembly within 10 minutes after the FIPG application.
  20. SEPARATE TRANSFER ASSEMBLY Remove the transfer assembly from the overhaul attachment.
  21. INSTALL TRANSFER CASE STRAIGHT PIN Using a plastic hammer, drive the 4 transfer case straight pins into the transfer case positions shown in the illustration. TEXT IN ILLUSTRATION *1 10.8 to 11.8 mm (0.425 to 0.465 in.) *2 5.7 to 6.7 mm (0.224 to 0.264 in.)
  22. INSTALL TRANSFER DYNAMIC DAMPER Install the transfer dynamic damper with the 3 bolts to the transfer extension housing sub-assembly. Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
  23. INSTALL TRANSFER CASE BREATHER PLUG Using SST and a hammer, tap in a new breather plug. SST: 09612-10093 09612-10061
  24. INSTALL BREATHER OIL DEFLECTOR Install the breather oil deflector with the bolt. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf)
  25. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY Remove any FIPG material and be careful not to drop oil on the contact surfaces of the transfer case cover sub-assembly and the transfer case. Degrease the surfaces with a non-residue solvent. Apply FIPG to the transfer case cover sub-assembly. FIPG Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Install the transfer case cover sub-assembly with the 6 bolts. Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) NOTE: Wait for at least 1 hour after installing the transfer case cover sub-assembly before adding transfer oil. Assemble the transfer case cover sub-assembly within 10 minutes after the FIPG application. Install the transfer case cover sub-assembly with the new 2 bolts. Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
  26. INSTALL TRANSFER DRAIN PLUG Install a new gasket to the transfer drain plug. Install the transfer drain plug to the transfer assembly. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
  27. INSTALL NO. 1 TRANSFER CASE PLUG Install a new gasket to the No. 1 transfer case plug. Install the No. 1 transfer case plug to the transfer assembly. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
  28. INSTALL NO. 2 TRANSFER CASE PLUG Install a new gasket to the No. 2 transfer case plug. Install the No. 2 transfer case plug to the transfer assembly. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
  29. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT Install the 4 new transfer and transaxle setting stud bolts to the transfer case positions shown in the illustration. TEXT IN ILLUSTRATION *1 Transaxle *2 Transfer Stud bolt length a 30 mm (1.1811 in.) b 12 mm (0.4724 in.) c 22 mm (0.8661 in.) Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) NOTE: Install the sealed side of the stud bolt to the transfer.

Scheme 111

Scheme 111: INSTALLATION
Scheme 111: INSTALLATION
  1. INSTALL TRANSFER ASSEMBLY Install the 4 new transfer and transaxle setting stud bolts to the transaxle case positions shown in the illustration. Stud bolt length a 22 mm (0.866 in.) b 25 mm (0.984 in.) c 5 mm (0.197 in.) Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) NOTE: Install the sealed side of the stud bolt to the transaxle assembly. Install the transfer assembly to the transaxle assembly with the 8 nuts. Torque: 69 N*m (700 kgf*cm, 51 ft.*lbf) NOTE: Install the transfer assembly to the transaxle assembly horizontally. Do not touch the transfer assembly oil seals during installation.
  2. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY . Refer to «INSTALLATION - Step 7»(ref-400805-S32594941712011051800000)
  3. INSTALL TRANSFER STIFFENER PLATE RH . Refer to «INSTALLATION - Step 7»(ref-400790-S30060480932011051800000)
  4. INSTALL WIRE HARNESS . Refer to «INSTALLATION - Step 9»(ref-400805-S32594941712011051800000)
  5. INSTALL TCM . Refer to «INSTALLATION - Step 1»(ref-400805-S03875796442011051800000)
  6. INSTALL MANIFOLD STAY . Refer to «INSTALLATION - Step 8»(ref-400790-S30060480932011051800000)
  7. INSTALL RADIATOR PIPE CLAMP . Refer to «INSTALLATION - Step 9»(ref-400790-S30060480932011051800000)
  8. INSTALL STARTER ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-400787-S06355397292011051800000)
  9. INSTALL FRONT FRAME ASSEMBLY . Refer to «INSTALLATION - Step 21»(ref-400790-S30060480932011051800000)
  10. INSTALL STEERING LINK ASSEMBLY . Refer to «INSTALLATION - Step 3»(ref-400820-S30494330852011051800000)
  11. INSTALL FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY
  12. INSTALL FRONT NO. 1 STABILIZER BRACKET LH . Refer to «INSTALLATION - Step 5»(ref-400810-S18047890532011051800000)
  13. INSTALL FRONT NO. 1 STABILIZER BRACKET RH . Refer to «INSTALLATION - Step 25»(ref-400790-S30060480932011051800000)
  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE HINT: See the steps from "Install Engine Assembly with Transaxle" through "Install Engine Room Side Cover LH". Refer to «INSTALLATION»(ref-400790-S12807558572011051800000) .

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