Transfer Case (Service Information): Overview Toyota Venza I

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1. INSPECT TRANSFER OIL Remove the No. 1 transfer case plug and gasket. Check that the oil level is between 0 and 5 mm (0 and 0.197 in.) from the bottom lip of the case plug hole. NOTE: When inspecting the transfer oil, make sure the vehicle is level. An excessively large or small amount of oil may cause damage. After adding oil, drive the vehicle and recheck the oil level. Check for oil leakage if the oil level is low. Install a new gasket onto the No. 1 transfer case plug and then tighten the plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
2. ADJUST TRANSFER OIL Remove the No. 1 transfer case plug and gasket. Add oil until the oil level is between 0 and 5 mm (0 and 0.197 in.) from the bottom lip of the case plug hole. NOTE: When adding transfer oil, make sure the vehicle is level. Add oil slowly, waiting several minutes between each addition. An excessively large or small amount of oil may cause damage. After adding oil, drive the vehicle and recheck the oil level. After waiting for approximately 5 minutes, recheck the oil level. Install a new gasket onto the No. 1 transfer case plug and then tighten the plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)

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1. REMOVE TRANSFER ASSEMBLY Refer to «REMOVAL»(ref-394815-S30137962202011040800000).
2. 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.
3. INSTALL TRANSFER CASE FRONT OIL SEAL Using SST, drive in 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.) NOTE: Do not tilt the oil seal during installation. Apply a small amount of MP grease to the lip of the oil seal.
4. INSTALL TRANSFER ASSEMBLY Refer to «INSTALLATION»(ref-394815-S30085948572011040800000).

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1. DRAIN TRANSFER OIL Remove the transfer drain plug and gasket to drain the transfer oil. Install a new gasket and the transfer drain plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
2. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Refer to «REMOVAL»(ref-394615-S11580929592011040800000).
3. 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.
4. INSTALL TRANSFER CASE FRONT OIL SEAL Using SST, drive in a new transfer case front oil seal into the transfer 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 (1.319 to 1.358 in.) NOTE: Do not tilt the oil seal during installation. Apply a small amount of MP grease to the lip of the oil seal.
5. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Refer to «INSTALLATION»(ref-394615-S12730120772011040800000).
6. ADD TRANSFER OIL
7. INSPECT TRANSFER OIL See step 1

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1. REMOVE TAIL EXHAUST PIPE ASSEMBLY. Refer to «REMOVAL - Step 6»(ref-394807-S20214007982011040800000)
2. REMOVE CENTER EXHAUST PIPE ASSEMBLY. Refer to «REMOVAL - Step 8»(ref-394807-S20214007982011040800000)
3. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY. Refer to «REMOVAL - Step 5»(ref-394615-S02945216812011040800000)
4. 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.
5. INSTALL TRANSFER CASE REAR OIL SEAL Using SST and a hammer, drive in a new transfer case rear oil seal into the transfer extension housing sub-assembly 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.) NOTE: Do not tilt the oil seal during installation. Apply a small amount of MP grease to the lip of the oil seal.
6. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY. Refer to «INSTALLATION - Step 1»(ref-394615-S41186447932011040800000)
7. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY. Refer to «INSTALLATION - Step 2»(ref-394615-S41186447932011040800000)
8. INSTALL CENTER EXHAUST PIPE ASSEMBLY. Refer to «INSTALLATION - Step 4»(ref-394807-S15559995042011040800000)
9. INSTALL TAIL EXHAUST PIPE ASSEMBLY. Refer to «INSTALLATION - Step 6»(ref-394807-S15559995042011040800000)
10. INSPECT TRANSFER OIL See step 1
11. INSPECT EXHAUST GAS LEAK

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1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Refer to «REMOVAL»(ref-394809-S14728256442011040800000) for 2GR-FE Refer to «REMOVAL»(ref-394814-S17624919102011040800000) for 1AR-FE
2. REMOVE FRONT NO. 1 STABILIZER BRACKET LH. Refer to «REMOVAL - Step 4»(ref-394797-S12225558082011040800000)
3. REMOVE FRONT NO. 1 STABILIZER BRACKET RH HINT: Perform the same procedure as for the LH side.
4. REMOVE FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY
5. REMOVE STEERING LINK ASSEMBLY. Refer to «REMOVAL - Step 11»(ref-394816-S24523012202011040800000)
6. REMOVE FRONT FRAME ASSEMBLY (for 2GR-FE) . Refer to «REMOVAL - Step 70»(/toyota/venza/i-2008-2012/remont/mechanical/#engine-mechanical-2gr-fe-service-information)
7. SEPARATE REAR ENGINE MOUNTING INSULATOR ASSEMBLY (for 1AR-FE) . Refer to «REMOVAL - Step 83»(/toyota/venza/i-2008-2012/remont/mechanical/#engine-mechanical-1ar-fe-service-information)
8. REMOVE FRONT FRAME ASSEMBLY (for 1AR-FE) . Refer to «REMOVAL - Step 84»(/toyota/venza/i-2008-2012/remont/mechanical/#engine-mechanical-1ar-fe-service-information)
9. REMOVE STARTER ASSEMBLY (for 2GR-FE). Refer to «REMOVAL - Step 7»(ref-394800-S22605417522011040800000)
10. REMOVE STARTER ASSEMBLY (for 1AR-FE). Refer to «REMOVAL - Step 6»(ref-394779-S30768277022011040800000)
11. REMOVE MANIFOLD STAY (for 2GR-FE) . Refer to «REMOVAL - Step 80»(/toyota/venza/i-2008-2012/remont/mechanical/#engine-mechanical-2gr-fe-service-information)
12. REMOVE TRANSFER STIFFENER PLATE RH (for 2GR-FE) . Refer to «REMOVAL - Step 81»(/toyota/venza/i-2008-2012/remont/mechanical/#engine-mechanical-2gr-fe-service-information)
13. REMOVE TRANSFER STIFFENER PLATE RH (for 1AR-FE) . Refer to «REMOVAL - Step 89»(/toyota/venza/i-2008-2012/remont/mechanical/#engine-mechanical-1ar-fe-service-information)
14. SEPARATE WIRE HARNESS (for 2GR-FE). Refer to «REMOVAL - Step 11»(ref-394809-S07867382922011040800000)
15. SEPARATE WIRE HARNESS (for 1AR-FE). Refer to «REMOVAL - Step 11»(ref-394814-S39250140672011040800000)
16. REMOVE FLEXIBLE HOSE BRACKET SUB-ASSEMBLY (for 2GR-FE). Refer to «REMOVAL - Step 12»(ref-394809-S07867382922011040800000)
17. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2GR-FE). Refer to «REMOVAL - Step 13»(ref-394809-S07867382922011040800000)
18. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 1AR-FE). Refer to «REMOVAL - Step 12»(ref-394814-S39250140672011040800000)
19. REMOVE TRANSFER ASSEMBLY Remove the 2 bolts and 6 nuts. Using a plastic hammer, remove the transfer assembly from the transaxle assembly. NOTE: Remove the transfer assembly from the transaxle assembly without tilting it. During removal, do not hold the transfer assembly by the oil seals on either side of the assembly.

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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 NO. 1 TRANSFER CASE COVER Remove the 8 bolts. Using a brass bar and a hammer, remove the No. 1 transfer case cover 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 DRIVE 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 front transfer driven pinion 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
26. REMOVE RING GEAR MOUNTING CASE BEARING Remove the ring gear mounting case bearing (outer race) from the transfer ring gear mounting case. Using SST, remove the ring gear mounting case bearing (inner race) 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) 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) 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 10 bolts. NOTE: Confirm whether the bolts are precoated or uncoated as the tightening torque is different for each type. 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 transfer driven pinion rear bearing (outer race) to remove it from the transfer case.

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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 0.56 to 0.94 N*m (6 to 9 kgf*cm, 5 to 8 in.*lbf) with SST 0.40 to 0.67 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) HINT: Use a torque wrench with a fulcrum length of 130 mm (5.12 in.). Using SST and a torque wrench, measure the total preload. SST: 09326-20011 Preload (at Starting) Item Preload without SST 0.35 to 0.53 N*m (4 to 5 kgf*cm, 3 to 4 in.*lbf) + driven pinion preload with SST 0.25 to 0.38 N*m (3 to 4 kgf*cm, 3 to 3.3 in.*lbf) + driven pinion preload HINT: Use a torque wrench with a fulcrum length of 130 mm (5.12 in.).
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 DRIVE PINION Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue. Turn the driven pinion to rotate the ring gear 10 times or more clockwise and 10 times or more counterclockwise. Rotate the ring gear to inspect the tooth 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 RUNOUT OF RING GEAR 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 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.)

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1. INSTALL TRANSFER DRIVEN PINION REAR BEARING Using SST and a press, press the transfer 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 transfer 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 FRONT TRANSFER DRIVEN PINION BEARING Apply gear oil to the inner surface of the transfer case. TEXT IN ILLUSTRATION *1 Turn *2 Hold Using SST, install the front transfer driven pinion 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 without SST Torque: 270 to 420 N*m (2751 to 4280 kgf*cm, 198 to 308 ft.*lbf) with SST Torque: 254 to 396 N*m (2588 to 4035 kgf*cm, 186 to 291 ft.*lbf) HINT: Using a torque wrench with a fulcrum length of 840 mm (33.07 in.). NOTE: 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) 0.68 to 1.13 N*m (7 to 11 kgf*cm, 6 to 10 in.*lbf) New bearing (with SST) 0.49 to 0.81 N*m (5 to 8 kgf*cm, 5 to 7 in.*lbf) Reused bearing (without SST) 0.56 to 0.94 N*m (6 to 9 kgf*cm, 5 to 8 in.*lbf) Reused bearing (with SST) 0.40 to 0.67 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf) HINT: Use a torque wrench with a fulcrum length of 130 mm (5.12 in.). 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 pinion nut to reduce the preload.
6. INSTALL RING GEAR Clean the contact surfaces of the ring gear and transfer ring gear mounting case. TEXT IN ILLUSTRATION *1 Boiling Water Heat the ring gear in boiling water. Carefully remove the ring gear from the boiling water. Align the matchmarks and quickly install the ring gear to the transfer ring gear mounting case. for Seal Lock Bolt: Apply adhesive to 10 new bolts. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent After the moisture on the ring gear has completely evaporated, install the 10 bolts. TEXT IN ILLUSTRATION *1 Matchmark for Seal Lock Bolt Torque: 112 N*m (1142 kgf*cm, 82 ft.*lbf) except Seal Lock Bolt Torque: 78 N*m (790 kgf*cm, 57 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. Confirm whether the bolts are precoated (Seal Lock Bolt) or uncoated (except Seal Lock Bolt) as the tightening torque is different for each type. 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) into the transfer ring gear mounting case. SST: 09950-60010 09951-00420 Install the ring gear mounting case bearing (outer race) 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) 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) 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. TEXT IN ILLUSTRATION *1 Spacer *2 Cutout *3 Case Hole
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: Install 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 washer from the table and install it to meet the specified range. TEXT IN ILLUSTRATION *1 Ring Gear Mounting Case Washer WASHER THICKNESS Mark Thickness mm (in.) Mark Thickness mm (in.) 5Q 1.95 (0.0768) 7N 2.67 (0.1051) 5R 1.97 (0.0776) 7P 2.69 (0.1059) 5S 1.99 (0.0783) 7Q 2.71 (0.1067) 5T 2.01 (0.0791) 7R 2.73 (0.1075) 5U 2.03 (0.0799) 7S 2.75 (0.1083) 5V 2.05 (0.0807) 7T 2.77 (0.1091) 5W 2.07 (0.0815) 7U 2.79 (0.1098) 5X 2.09 (0.0823) 7V 2.81 (0.1106) 5Y 2.11 (0.0831) 7W 2.83 (0.1114) 5Z 2.13 (0.0839) 7X 2.85 (0.1122) 6F 2.15 (0.0846) 7Y 2.87 (0.1130) 6G 2.17 (0.0854) 7Z 2.89 (0.1138) 6H 2.19 (0.0862) 8F 2.91 (0.1146) 6J 2.21 (0.0870) 8G 2.93 (0.1154) 6K 2.23 (0.0878) 8H 2.95 (0.1161) 6L 2.25 (0.0886) 8J 2.97 (0.1169) 6M 2.27 (0.0894) 8K 2.99 (0.1177) 6N 2.29 (0.0902) 8L 3.01 (0.1185) 6P 2.31 (0.0909) 8M 3.03 (0.1193) 6Q 2.33 (0.0917) 8N 3.05 (0.1201) 6R 2.35 (0.0925) 8P 3.07 (0.1209) 6S 2.37 (0.0933) 8Q 3.09 (0.1217) 6T 2.39 (0.0941) 8R 3.11 (0.1224) 6U 2.41 (0.0949) 8S 3.13 (0.1232) 6V 2.43 (0.0957) 8T 3.15 (0.1240) 6W 2.45 (0.0965) 8U 3.17 (0.1248) 6X 2.47 (0.0972) 8V 3.19 (0.1256) 6Y 2.49 (0.0980) 8W 3.21 (0.1264) 6Z 2.51 (0.0988) 8X 3.23 (0.1272) 7F 2.53 (0.0996) 8Y 3.25 (0.1280) 7G 2.55 (0.1004) 8Z 3.27 (0.1287) 7H 2.57 (0.1012) 9D 3.29 (0.1295) 7J 2.59 (0.1020) 9E 3.31 (0.1303) 7K 2.61 (0.1028) 9F 3.33 (0.1311) 7L 2.63 (0.1035) 9G 3.35 (0.1319) 7M 2.65 (0.1043) 9H 3.37 (0.1327)
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. Turn the driven pinion to rotate the ring gear 10 times or more clockwise and 10 times or more counterclockwise. 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 (0.1000) CC 2.18 (0.0858) RA 2.56 (0.1008) DB 2.20 (0.0866) RB 2.58 (0.1016) EA 2.22 (0.0874) RC 2.60 (0.1024) EC 2.24 (0.0882) SA 2.62 (0.1031) FB 2.26 (0.0890) SB 2.64 (0.1039) GA 2.28 (0.0898) SC 2.66 (0.1047) GC 2.30 (0.0906) TA 2.68 (0.1055) HB 2.32 (0.0913) TB 2.70 (0.1063) JA 2.34 (0.0921) TC 2.72 (0.1071) 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) 0.48 to 0.70 N*m (5 to 7 kgf*cm, 5 to 6 in.*lbf) + Driven pinion preload New bearing (with SST) 0.35 to 0.50 N*m (4 to 5 kgf*cm, 4 to 4.4 in.*lbf) + Driven pinion preload Reused bearing (without SST) 0.35 to 0.53 N*m (4 to 5 kgf*cm, 4 to 4.6 in.*lbf) + Driven pinion preload Reused bearing (with SST) 0.25 to 0.38 N*m (3 to 3.8 kgf*cm, 3 to 3.3 in.*lbf) + Driven pinion preload HINT: Use a torque wrench with a fulcrum length of 130 mm (5.12 in.). 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: MM (IN.) Mark Thickness Mark Thickness G7 2.47 (0.0972) M7 3.47 (0.1366) G8 2.49 (0.0980) M8 3.49 (0.1374) G9 2.51 (0.0988) M9 3.51 (0.1382) H0 2.53 (0.0996) N0 3.53 (0.1390) H1 2.55 (0.1004) N1 3.55 (0.1398) H2 2.57 (0.1012) N2 3.57 (0.1406) H3 2.59 (0.1020) N3 3.59 (0.1413) H4 2.61 (0.1028) N4 3.61 (0.1421) H5 2.63 (0.1035) N5 3.63 (0.1429) H6 2.65 (0.1043) N6 3.65 (0.1437) H7 2.67 (0.1051) N7 3.67 (0.1445) H8 2.69 (0.1059) N8 3.69 (0.1453) H9 2.71 (0.1067) N9 3.71 (0.1461) J0 2.73 (0.1075) P0 3.73 (0.1469) J1 2.75 (0.1083) P1 3.75 (0.1476) J2 2.77 (0.1091) P2 3.77 (0.1484) J3 2.79 (0.1098) P3 3.79 (0.1492) J4 2.81 (0.1106) P4 3.81 (0.1500) J5 2.83 (0.1114) P5 3.83 (0.1508) J6 2.85 (0.1122) P6 3.85 (0.1516) J7 2.87 (0.1130) P7 3.87 (0.1524) J8 2.89 (0.1138) P8 3.89 (0.1531) J9 2.91 (0.1146) P9 3.91 (0.1539) K0 2.93 (0.1154) Q0 3.93 (0.1547) K1 2.95 (0.1161) Q1 3.95 (0.1555) K2 2.97 (0.1169) Q2 3.97 (0.1563) K3 2.99 (0.1177) Q3 3.99 (0.1571) K4 3.01 (0.1185) Q4 4.01 (0.1579) K5 3.03 (0.1193) Q5 4.03 (0.1587) K6 3.05 (0.1201) Q6 4.05 (0.1594) K7 3.07 (0.1209) Q7 4.07 (0.1602) K8 3.09 (0.1217) Q8 4.09 (0.1610) K9 3.11 (0.1224) Q9 4.11 (0.1618) L0 3.13 (0.1232) R0 4.13 (0.1626) L1 3.15 (0.1240) R1 4.15 (0.1634) L2 3.17 (0.1248) R2 4.17 (0.1642) L3 3.19 (0.1256) R3 4.19 (0.1650) L4 3.21 (0.1264) R4 4.21 (0.1657) L5 3.23 (0.1272) R5 4.23 (0.1665) L6 3.25 (0.1280) R6 4.25 (0.1673) L7 3.27 (0.1287) R7 4.27 (0.1681) L8 3.29 (0.1295) R8 4.29 (0.1689) L9 3.31 (0.1303) R9 4.31 (0.1697) M0 3.33 (0.1311) S0 4.33 (0.1705) M1 3.35 (0.1319) S1 4.35 (0.1713) M2 3.37 (0.1327) S2 4.37 (0.1720) M3 3.39 (0.1335) S3 4.39 (0.1728) M4 3.41 (0.1343) S4 4.41 (0.1736) M5 3.43 (0.1350) S5 4.43 (0.1744) M6 3.45 (0.1358) S6 4.45 (0.1752) 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 (1.319 to 1.358 in.) NOTE: Do not install the oil seal at an angle. 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 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: 09820-00031
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 NO. 1 TRANSFER CASE COVER Remove any FIPG material and be careful not to drop oil on the contact surfaces of the No. 1 transfer case cover and the transfer case. Degrease the surfaces with a non-residue solvent. Apply FIPG to the No. 1 transfer case cover. FIPG Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Install the No. 1 transfer case cover with the 6 bolts. Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) NOTE: Wait for at least one hour after installing the No. 1 transfer case cover before adding transfer oil. Assemble the No. 1 transfer case cover within 10 minutes after the FIPG application. Install the No. 1 transfer case cover 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 new 4 transfer and transaxle setting stud bolts to the transfer case positions shown in the illustration. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) HINT: Install the shorter end of the stud bolts to the transfer. TEXT IN ILLUSTRATION *1 Transaxle Side *2 Transfer Side *3 30 mm (1.1811 in.) *4 12 mm (0.4724 in.) *5 22 mm (0.8661 in.)

See also:
• REMOVAL - Step 70
• REMOVAL - Step 83
• REMOVAL - Step 27