Transfer Case -VF2A: Other Toyota Tundra I рестайлинг

PRECAUTION

When working with FIPG material, you must observe the following.

1. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces.
2. Thoroughly clean all components to remove all the loose material.
3. Clean both sealing surfaces with a non-residue solvent.
4. Apply FIPG in approx. 1 mm (0.04 in.) wide bead along the sealing surface.
5. Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

COMPONENTS

HINT: VF2A transfer is used for the vehicles with 5VZ-FE engine installed.

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1. REMOVE TRANSFER SHIFT LEVER Remove the transfer shift lever knob. Remove the 4 screws, shift lever boot retainer and shift lever boot. Using snap ring pliers, remove the snap ring and pull out the transfer shift lever. HINT: Shift the transfer shift lever to the "H4" position.
2. DISCONNECT BREATHER HOSE Disconnect the breather hose from the transfer.
3. RAISE VEHICLE AND DRAIN TRANSFER OIL
4. REMOVE FRONT AND REAR PROPELLER SHAFTS (See REMOVAL )
5. REMOVE DYNAMIC DAMPER Remove the 2 bolts and dynamic damper from the transfer.
6. REMOVE CROSSMEMBER Support the transmission rear side with a transmission jack. Remove the 4 bolts. Remove the 4 bolts, nuts and crossmember.
7. REMOVE ENGINE REAR MOUNTING Remove the 4 bolts and engine rear mounting from the transfer adaptor.
8. DISCONNECT VEHICLE SPEED SENSOR AND TRANSFER DETECTION SWITCH CONNECTORS (See «COMPONENTS»(ref-181825-S28492227202005080400000) )
9. REMOVE TRANSFER Support the transfer with another transmission jack. Remove the 8 transfer mounting bolts. Pull out the transfer from the transfer adaptor down and toward the rear.

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1. RAISE VEHICLE
2. INSTALL TRANSFER Raise the transfer and install it to the transfer adaptor with the 8 transfer mounting bolts. Torque: 24 N.m (240 kgf.cm, 17 ft.lbf) NOTE: Take care not to damage the lip of the transfer adaptor rear oil seal with the transfer input shaft.
3. CONNECT VEHICLE SPEED SENSOR AND TRANSFER DETECTION SWITCH CONNECTORS (See «COMPONENTS»(ref-181825-S28492227202005080400000) )
4. INSTALL ENGINE REAR MOUNTING Install the engine rear mounting to the transfer adaptor with the 4 bolts. Torque: 65 N.m (650 kgf.cm, 48 ft.lbf)
5. INSTALL CROSSMEMBER Install the crossmember with the 4 bolts and nuts. Torque: 72 N.m (740 kgf.cm, 53 ft.lbf) Install the 4 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) Remove the transmission jacks.
6. INSTALL DYNAMIC DAMPER Install the dynamic damper to the transfer with the 2 bolts. Torque: 38 N.m (380 kgf.cm, 28 ft.lbf)
7. INSTALL FRONT AND REAR PROPELLER SHAFTS (See INSTALLATION )
8. FILL TRANSFER OIL Oil grade: API GL-4 or GL-5 Viscosity: SAE 75W-90 Capacity: 1.0 liters (1.1 US qts, 0.9 Imp. qts) Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
9. CONNECT BREATHER HOSE Connect the breather hose to the transfer. Hose installation depth: 13 mm (0.51 in.) or more
10. INSTALL TRANSFER SHIFT LEVER Lower the vehicle. Install the tip of the transfer shift lever as shown in the illustration. HINT: Apply MP grease to the tip of the transfer shift lever. Pressing down on the transfer shift lever cap, and using snap ring pliers, install the snap ring. Install the shift lever boot and shift lever boot retainer with the 4 screws. Install the transfer shift lever knob.
11. DO ROAD TEST Check for abnormal noises and smooth shifting.

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1. REMOVE VEHICLE SPEED SENSOR ASSEMBLY Remove the bolt and vehicle speed sensor assembly. Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) Remove the O-ring from the vehicle speed sensor assembly. HINT: At the time of re-assembly, install a new O-ring. Remove the clip and vehicle speed sensor driven gear.
2. M/T (w/ Diff. lock, or/and ABS) and A/T: REMOVE TRANSFER L4 POSITION SWITCH WITH GASKET Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) HINT: At the time of re-assembly, install a new gasket.
3. REMOVE TRANSFER 4WD POSITION SWITCH WITH GASKET Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) HINT: At the time of reassembly, install a new gasket.
4. A/T: REMOVE TRANSFER NEUTRAL POSITION SWITCH WITH GASKET Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) HINT: At the time of reassembly, install a new gasket.
5. M/T: REMOVE 2 PLUGS AND GASKETS OF FRONT CASE Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) HINT: At the time of reassembly, please refer to the following items. Install a new gasket. The input and output shafts rotate smoothly. Shifting can be made smoothly to all positions.
6. REMOVE PROTECTOR Remove the 4 bolts and protector. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
7. A/T: REMOVE SHIFT GEAR HEAD NO. 1 AND NO. 2 Using a pin punch and hammer, drive out the 2 slotted spring pins. Remove the 2 shift gear heads.
8. REMOVE FRONT BEARING RETAINER Remove the 5 bolts. Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) HINT: At the time of reassembly, apply liquid sealer to the bolt threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a plastic hammer, tap the front bearing retainer and remove it. HINT: At the time of reassembly, please refer to the following items. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the front bearing retainer. Apply FIPG to the front bearing retainer, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
9. M/T: REMOVE CONTROL RETAINER AND OIL DEFLECTOR Remove the 4 bolts, control retainer, gasket and oil deflector. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) HINT: At the time of reassembly, install a new gasket. Remove the select return spring from the control retainer.
10. A/T: REMOVE UPPER COVER AND OIL DEFLECTOR Remove the 4 bolts, upper cover, 2 gaskets and oil deflector. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) HINT: At the time of reassembly, install 2 new gaskets.
11. REMOVE FRONT COMPANION FLANGE Using a chisel and hammer, loosen the staked part of the nut. HINT: At the time of reassembly, stake a new lock nut. Using SST to hold the flange, remove the companion flange lock nut. SST 09330-00021 Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf) Using SST, remove the companion flange. SST 09950-4001 1 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
12. REMOVE REAR COMPANION FLANGE Remove the rear companion flange in the same way as the front companion flange. HINT: At the time of reassembly, please refer to the following items. Front companion flange bolts are thin. Rear companion flange bolts are thick.
13. REMOVE EXTENSION HOUSING Remove the 5 bolts. Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) HINT: At the time of reassembly, apply liquid sealer to the bolt threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a plastic hammer, tap the extension housing and remove it. HINT: At the time of reassembly, please refer to the following items. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the extension housing. Apply FIPG to the extension housing, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
14. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR Remove the 2 output shaft washers and vehicle speed sensor drive gear. Using a magnetic finger, remove the ball from the rear output shaft.
15. SEPARATE FRONT CASE AND REAR CASE Remove the 12 bolts. Torque: 28 N.m (285 kgf.cm, 21 ft.lbf) Using a screwdriver, separate the front case and rear case. HINT: At the time of reassembly, please refer to the following items. Shift the high and low sleeve to low side (rear side) and assemble the front case and rear case. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the rear case. Apply FIPG to the rear case, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
16. REMOVE STRAIGHT SCREW PLUG, SPRING AND LOCKING BALL Using a hexagon wrench, remove the 2 plugs. Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) HINT: At the time of reassembly, apply liquid sealer to the plug threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a magnetic finger, remove the 2 springs and balls from the both holes.
17. REMOVE FRONT DRIVE FORK SHAFT, SHIFT FORK, SPRING AND STOPPER Mount the rear case in a vise. NOTE: Be careful not to damage the sealing surface. Using a pin punch and hammer, drive out the 2 slotted spring pins. HINT: When the pin is removed from the front drive fork shaft, the shaft will spring loose if the pin punch is removed, so keep the pin punch inserted in the shaft hole. HINT: At the time of reassembly, please refer to the following items. Using a pin punch and hammer, drive in the 2 slotted spring pins. When installing the pin in the front drive fork shaft, push the shaft towards the rear case and install the pin while the spring is compressed. Hold the front drive fork shaft in place by hand, when removing the pin punch. Remove the front drive fork shaft, shift fork, spring and stopper. HINT: At the time of reassembly, please refer to the following items. Place the front drive shift fork into the groove of the clutch sleeve. Make sure that the shift fork and stopper are installed in the correct direction. Using a magnetic finger, remove the straight pin. HINT: At the time of reassembly, apply gear oil to the straight pin and insert it into the case hole.
18. REMOVE HIGH AND LOW FORK SHAFT AND SHIFT FORK HINT: At the time of reassembly, please refer to the following items. Place the high and low shift fork into the groove of the clutch sleeve. Make sure that the shift fork is installed in the correct direction.
19. REMOVE REAR OUTPUT SHAFT ASSEMBLY, DRIVEN SPROCKET ASSEMBLY AND CHAIN Using a snap ring expander, remove the snap ring. Using a plastic hammer, tap the rear case while with pulling the rear output shaft assembly and driven sprocket assembly. HINT: At the time of reassembly, please refer to the following item. If necessary, heat the rear case to about 50 to 80°C (122 to 176°F). Remove the chain.
20. M/T: REMOVE SYNCHRONIZER RING FROM INPUT SHAFT HINT: At the time of reassembly, please refer to the following items. Apply MP grease to the synchronizer ring. Align the synchronizer ring slots with the shifting keys, and install the synchronizer ring on the high and low clutch hub.
21. REMOVE SEPARATOR WITH OIL STRAINER AND MAGNET Remove the 3 bolts, separator with the oil strainer and magnet. Torque: 7.5 N.m (80 kgf.cm, 69 in.lbf)
22. REMOVE OIL PUMP BODY ASSEMBLY Remove the 3 bolts and oil pump body assembly. Torque: 7.5 N.m (80 kgf.cm, 69 in.lbf)
23. REMOVE OIL PUMP DRIVE GEAR
24. REMOVE PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY Using a snap ring expander, remove the snap ring. Pull out the planetary gear assembly with the input shaft assembly. HINT: At the time of reassembly, please refer to the following item. If necessary, heat the front case to about 50 to 80°C (122 to 176°F).
25. REMOVE LOW GEAR SPLINE PIECE Using a screwdriver, remove the snap ring. HINT: At the time of reassembly, please refer to the following item. Be sure the end gap of the snap ring is not aligned with cutout portion of the planetary carrier. Remove the low gear spline piece.
26. REMOVE NEEDLE ROLLER BEARING FROM INPUT SHAFT ASSEMBLY HINT: At the time of reassembly, apply gear oil to the needle roller bearing.
27. REMOVE INPUT GEAR STOPPER AND THRUST BEARING Using a snap ring expander, remove the snap ring. HINT: At the time of reassembly, please refer to the following item. Select a snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) axial play. SPRING THICKNESS Mark Thickness mm (in.) A 2.10 to 2.15 (0.0827 to 0.0846) B 2.15 to 2.20 (0.0846 to 0.0866) C 2.20 to 2.25 (0.0866 to 0.0886) D 2.25 to 2.30 (0.0886 to 0.0906) E 2.30 to 2.35 (0.0906 to 0.0925) F 2.35 to 2.40 (0.0925 to 0.0945) G 2.40 to 2.45 (0.0945 to 0.0965) H 2.45 to 2.50 (0.0965 to 0.0984) J 2.50 to 2.55 (0.0984 to 0.1004) K 2.55 to 2.60 (0.1004 to 0.1024) L 2.60 to 2.65 (0.1024 to 0.1043) M 2.65 to 2.70 (0.1043 to 0.1063) N 2.70 to 2.75 (0.1063 to 0.1083) P 2.75 to 2.80 (0.1083 to 0.1102) Q 2.80 to 2.85 (0.1102 to 0.1122) R 2.85 to 2.90 (0.1122 to 0.1142) S 2.90 to 2.95 (0.1142 to 0.1161) T 2.95 to 3.00 (0.1161 to 0.1181) U 3.00 to 3.05 (0.1181 to 0.1201) Remove the input gear stopper, thrust washer and ball. HINT: At the time of reassembly, apply gear oil to the input gear stopper and thrust washer.
28. REMOVE INPUT SHAFT ASSEMBLY, THRUST BEARING AND RACE
29. REMOVE PLANETARY RING GEAR Using a screwdriver, remove the snap ring. HINT: At the time of reassembly, please refer to the following item. Be sure the end gap of the snap ring is not aligned with the upper side of the case. Remove the head screw plug, spring and pin. Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) HINT: At the time of reassembly, apply liquid sealer to the plug threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Remove the planetary ring gear. HINT: At the time of reassembly, please refer to the following item. Make sure that the ring gear is installed in the correct direction.