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Transfer Case: Other Toyota Highlander I facelift

Transfer Case 9 illustrations ~1280 words

PRECAUTION

  1. Before disassembly, clean the transfer assy and remove any deposited sand or mud to prevent it from entering the inside of the transfer during disassembly and assembly.
  2. When removing any light alloy part such as a transfer cover, do not pry it off with a tool like a screwdriver but tap it out with a plastic hammer.
  3. Always organize the removed parts properly and protect them away from dust.
  4. After cleaning and drying completely before installation, apply hypoid gear oil to each part. Do not use alkaline chemicals when cleansing aluminum or rubber parts and ring gear set bolts. Also, do not use any cleansing oil (ex. white gasoline) to clean the rubber parts such as O rings and oil seals.
  5. Sufficiently apply hypoid gear oil to any sliding surface or rotating part.
  6. Do not directly hold a part by vise. Make sure to put an aluminum sheet between them.
  7. Replace any damaged or deformed snap ring with new one.
  8. If mating surface of the case is scratched, it may cause oil leakage. Therefore, carefully avoid such damage when handling.
  9. Before applying a sealant, completely remove old sealant stuck on the sealed parts and clean them with white gasoline.
  10. Do not supply oil immediately after installing sealed parts. Allow 1 hour or more.
  11. Scratches on a contact surface with an oil seal, O ring or gasket may result in oil leakage. Carefully avoid such damage when handling.
  12. When press-fitting an oil seal, take care to prevent the oil seal lip and its periphery from being damaged.
  13. When replacing a bearing, replace both outer and inner races as one set.

Scheme 106

Scheme 106: PROBLEM SYMPTOMS TABLE
Scheme 106: PROBLEM SYMPTOMS TABLE

Scheme 107

Scheme 107: COMPONENTS
Scheme 107: COMPONENTS

Scheme 108

Scheme 108: ADJUSTMENT
Scheme 108: ADJUSTMENT
  1. REMOVE EXHAUST PIPE ASSY FRONT (3MZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S18540808582006032800000) )
  2. REMOVE EXHAUST PIPE ASSY FRONT (2AZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S41569326612006032800000) )
  3. INSPECT TRANSFER OIL Remove the No.1 plug and gasket. Check the oil level is within 0 to 5 mm (0 to 0.1968 in.) down from the lowest end of the hole for No.1 plug. NOTE: When changing oil, recheck the oil level after driving. Excessively large or small quantity of oil may cause some trouble. When the oil level is too low, check for oil leakage. Tighten the No.1 plug with a new gasket. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
  4. ADD TRANSFER OIL Remove the No.1 plug and gasket and supply oil. NOTE: When supplying oil, pour it slowly. Repeat supplying oil several times at several minutes interval. HINT: Within 0 to 5 mm (0 to 0.1968 in.) down from the lowest end of the hole for the No.1 plug. After leaving it alone for 5 min., check the oil level again. Tighten the No. 1 plug with a new gasket.
  5. INSTALL EXHAUST PIPE ASSY FRONT (3MZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S18540808582006032800000) )
  6. INSTALL EXHAUST PIPE ASSY FRONT (2AZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S41569326612006032800000) )

Scheme 109

Scheme 109: REPLACEMENT
Scheme 109: REPLACEMENT

Scheme 110

Scheme 110
Scheme 110
  1. REMOVE EXHAUST PIPE ASSY FRONT (3MZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S18540808582006032800000) )
  2. REMOVE EXHAUST PIPE ASSY FRONT (2AZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S41569326612006032800000) )
  3. DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug, gasket and drain ATF. Install a new gasket and drain plug.
  4. REMOVE TRANSFER CASE NO.1 PLUG
  5. REMOVE TRANSFER DRAIN PLUG Remove the transfer drain plug, drain gasket and bleed the drain transfer oil.
  6. REMOVE FRONT WHEEL
  7. REMOVE FRONT DRIVE SHAFT ASSY RH (SEE «FRONT DRIVE SHAFT»(ref-226420-S16706914332006032900000) ) SST 09520-01010, 09520-24010 (09520-32040)
  8. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL Using SST, remove the right bearing retainer oil seal. SST 09308-00010 NOTE: Do not damage the oil-seal-fitted surface of the case.
  9. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL Using SST, drive a new oil seal into the case to the position shown in the illustration. SST 09223-46011 NOTE: Do not install the oil seal obliquely. Apply small amount of MP grease to the oil seal lip.
  10. INSTALL FRONT DRIVE SHAFT ASSY RH (SEE «FRONT DRIVE SHAFT»(ref-226420-S16706914332006032900000) )
  11. INSTALL FRONT WHEEL
  12. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
  13. INSPECT AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (SEE «AUTOMATIC TRANSAXLE FLUID (ATM)»(ref-226424-S33274812062006032900000) )
  14. INSTALL TRANSFER DRAIN PLUG Install the drain plug with a new gasket.
  15. INSTALL TRANSFER CASE NO.1 PLUG Supply oil up to the level 0 to 5 mm (0 to 0.1968 in.) down from the lowest end of the plug hole. Oil quantity: 0.9 L (0.95 US qts, 0.71 Imp.qts) NOTE: When supplying oil, be careful to do it slowly. Install the plug No. 1 with a new gasket. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
  16. INSTALL EXHAUST PIPE ASSY FRONT (3MZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S18540808582006032800000) )
  17. INSTALL EXHAUST PIPE ASSY FRONT (2AZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S41569326612006032800000) )
  18. CHECK FOR EXHAUST GAS LEAKS
  19. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE «FRONT WHEEL ALIGNMENT»(ref-226416-S16095735362006032800000) )
  20. CHECK ABS SPEED SENSOR SIGNAL (SEE «PRE-CHECK»(ref-226383-S26855084272006032700000) )

Scheme 111

Scheme 111: REPLACEMENT
Scheme 111: REPLACEMENT

Scheme 112

Scheme 112
Scheme 112
  1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226410-S37790286992006032800000) )
  2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226410-S11713569722006032800000) )
  3. REMOVE TRANSVERSE ENGINE, ENGINE MOUNTING BRACKET (2AZ-FE ENGINE TYPE) (SEE «TRANSFER ASSY (4WD)»(ref-226421-S42661661312006032900000) )
  4. REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) (SEE «TRANSFER ASSY (4WD)»(ref-226421-S42661661312006032900000) )
  5. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226424-S28652024122006032900000) )
  6. REMOVE TRANSFER ASSY (SEE «TRANSFER ASSY (4WD)»(ref-226421-S42661661312006032900000) )
  7. REMOVE CTR DIFFERENTIAL LOCK SLEEVE (SEE «TRANSFER ASSY (4WD)»(ref-226421-S42661661312006032900000) ) SST 09308-00010
  8. REMOVE TRANSFER CASE OIL SEAL Using SST, remove the oil seal from the case. SST 09308-00010 NOTE: Do not damage the oil-seal-fitted surface of the case.
  9. INSTALL TRANSFER CASE OIL SEAL Using SST, drive a new oil seal into the case to the position shown in the illustration. SST 09387-00010, 09950-70010 (09951-07150) NOTE: Do not install it obliquely. Apply small amount of MP grease to the oil seal lip.
  10. INSTALL CTR DIFFERENTIAL LOCK SLEEVE (SEE «TRANSFER ASSY (4WD)»(ref-226421-S42661661312006032900000) ) SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)
  11. INSTALL TRANSFER ASSY (SEE «TRANSFER ASSY (4WD)»(ref-226421-S42661661312006032900000) )
  12. INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) (SEE «TRANSFER ASSY (4WD)»(ref-226421-S42661661312006032900000) )
  13. INSTALL TRANSVERSE ENGINE, ENGINE MOUNTING BRACKET (2AZ-FE ENGINE TYPE) (SEE «TRANSFER ASSY (4WD)»(ref-226421-S42661661312006032900000) )
  14. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226424-S28652024122006032900000) )
  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226410-S37790286992006032800000) )
  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226410-S11713569722006032800000) )

Scheme 113

Scheme 113: REPLACEMENT
Scheme 113: REPLACEMENT

Scheme 114

Scheme 114
Scheme 114
  1. REMOVE EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S18540808582006032800000) )
  2. REMOVE EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S41569326612006032800000) )
  3. REMOVE TRANSFER CASE NO.1 PLUG
  4. REMOVE TRANSFER DRAIN PLUG
  5. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (SEE «PROPELLER W/CENTER BEARING SHAFT ASSY (4WD)»(ref-226420-S07628102592006032900000) )
  6. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL Using SST, remove the oil seal from the extension housing. SST 09308-00010 NOTE: Be careful not to damage the oil-seal-fitted surface and the inside surface of the bush.
  7. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL Using SST, drive a new oil seal into the extension housing to the position shown in the illustration. SST 09550-60010 (09951-00380, 09951-00580, 09952-06010), 09950-70010 (09951-07150) NOTE: Do not install the oil seal obliquely. Apply small amount of MP grease to the oil seal lip.
  8. TEMPORARILY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (SEE «PROPELLER W/CENTER BEARING SHAFT ASSY (4WD)»(ref-226420-S07628102592006032900000) )
  9. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (SEE «PROPELLER W/CENTER BEARING SHAFT ASSY (4WD)»(ref-226420-S07628102592006032900000) )
  10. INSTALL TRANSFER DRAIN PLUG Install the drain plug with a new gasket.
  11. INSTALL TRANSFER CASE NO.1 PLUG Supply oil up to the level 0 to 5 mm (0 to 0.1968 in.) down from the lowest end of the plug hole. Oil quantity: 0.9 L (0.95 US qts, 0.71 Imp.qts) NOTE: When supplying oil, be careful to do it slowly. Install the No. 1 plug with a new gasket. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
  12. INSTALL EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S18540808582006032800000) )
  13. INSTALL EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE «REPLACEMENT»(ref-226411-S41569326612006032800000) )

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