Toyota Highlander manuals

Toyota Highlander Service Manual: Transfer ASSY (4WD)

OVERHAUL

HINT: COMPONENT: 3MZ-FE ENGINE: See page 14-134 2AZ-FE ENGINE: See page 14-15 AUTOMATIC TRANSMISSION (U151E/U151F): See page 40-18 TRANSFER: See page 31-3

1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 )

2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 )

3. REMOVE TRANSFER CASE NO.1 PLUG

REMOVE TRANSFER CASE NO.1 PLUG


(a) Remove the transfer case No.1 plug.

(b) Remove the gasket No.1 from the transfer case No.1 plug.

4. REMOVE TRANSFER CASE NO.2 PLUG

(a) Remove the transfer case No.2 plug.

(b) Remove the gasket No.2 from the transfer case No.2 plug.

5. REMOVE TRANSFER DRAIN PLUG

(a) Remove the transfer drain plug and bleed the transfer oil.

(b) Remove the drain gasket from the transfer drain plug.

6. REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE)

REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE)


(a) Remove the 5 bolts and the stiffener plate RH.

7. REMOVE ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE)

(a) Remove the 3 bolts and the engine mounting bracket RR.

8. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE) (SEE PAGE 40-20 )

9. REMOVE TRANSFER ASSY

REMOVE TRANSFER ASSY


(a) Remove the 2 bolts and 6 nuts.

(b) Using a plastic hammer, remove the transfer assy from the transaxle assy.

NOTICE:

10. REMOVE TRANSFER COVER GASKET

REMOVE TRANSFER COVER GASKET


(a) Remove the transfer cover gasket from the transfer assy.

11. REMOVE TRANSFER CASE BREATHER PLUG

REMOVE TRANSFER CASE BREATHER PLUG


(a) Using a screwdriver and a hammer, remove the transfer case breather plug from the transfer case cover No.1.

NOTICE: Be careful not to damage the contact surface of the case cover No.1.

12. REMOVE TRANSFER CASE COVER NO.1

REMOVE TRANSFER CASE COVER NO.1


(a) Remove the 8 bolts.

REMOVE TRANSFER CASE COVER NO.1


(b) Using a brass bar and a hammer, remove the transfer case cover No.1 from the transfer.

NOTICE: Be careful not to damage the contact surfaces of the case and cover.

13. REMOVE BREATHER OIL DEFLECTOR

REMOVE BREATHER OIL DEFLECTOR


(a) Remove the bolt and breather oil deflector from the transfer case cover No.1.

14. REMOVE TRANSFER DYNAMIC DAMPER

REMOVE TRANSFER DYNAMIC DAMPER


(a) Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing sub-assy.

15. REMOVE TRANSFER CASE STRAIGHT PIN

(a) Remove the 4 transfer case straight pins from the transfer case.

16. REMOVE TRANSFER & TRANSAXLE SETTING STUD BOLT

(a) Remove the 4 transfer & transaxle setting stud bolts.

17. FIX TRANSFER ASSY

(a) Fix the transfer assy to the overhaul attachment.

18. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR

REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR


(a) Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assy.

19. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL


(a) Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing.

SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.

20. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY

REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY


(a) Remove the 4 bolts.

REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY


(b) Using a plastic hammer, remove the transfer extension housing sub-assy from the transfer case.

21. INSPECT PRELOAD

INSPECT PRELOAD


(a) Using SST and a torque wrench, check the initial torque within the backlash range.

SST 09326-2001 1

Torque (preload): 0.9 to 1.4 NVm (9 to 14 kgfVcm, 8.0 to 12.4 in.Vlbf)

HINT:

(b) Using SST and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.

SST 09326-2001 1

Torque: Preload + 0.15 to 0.30 NVm (+1.6 to 3.1 kgfVcm, +1.3 to 2.7 in.Vlbf)

HINT:

22. INSPECT BACKLASH

 INSPECT BACKLASH


(a) Set the dial indicator perpendicular to the tooth face of the ring gear, fix the driven pinion and inspect the backlash while moving the gear.

Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.)

NOTICE: Inspect it at 3 points or more on the gear's periphery.

HINT: Write down the result.

23. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION


(a) Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate several times.

NOTICE: Inspect the tooth contact on the ring gear at 4 places or more.

(b) Proper washer location is shown in the illustration.

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION


24. REMOVE CTR DIFFERENTIAL LOCK SLEEVE

REMOVE CTR DIFFERENTIAL LOCK SLEEVE


(a) Using snap ring pliers, remove the shaft snap ring.

REMOVE CTR DIFFERENTIAL LOCK SLEEVE


(b) Using SST, remove the CTR differential lock sleeve.

SST 09308-00010

25. REMOVE O-RING

REMOVE O-RING


(a) Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.

NOTICE: Be careful not to damage the lock sleeve's groove for the O-ring.

26. REMOVE TRANSFER CASE OIL SEAL

REMOVE TRANSFER CASE OIL SEAL


(a) Using SST, remove the transfer case oil seal from the case.

SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the case.

27. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL

REMOVE TRANSFER RH BEARING RETAINER OIL SEAL


(a) Using SST, remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assy.

SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the retainer.

28. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY

REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY


(a) Remove the 7 bolts from the transfer RH bearing retainer sub-assy .

REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY


(b) Using a screwdriver and a hammer, create a clearance between the transfer RH bearing retainer sub-assy and the transfer case.

NOTICE: Be careful not to damage the transfer RH bearing retainer sub-assy and the transfer case.

REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY


(c) Using SST, remove the transfer RH bearing retainer subassy from the transfer case.

SST 09520-10021

29. REMOVE O-RING

REMOVE O-RING


(a) Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assy.

NOTICE: Be careful not to damage the retainer's grooves for the Orings.

30. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


(a) Fix the transfer RH bearing retainer sub-assy in a vise.

(b) Using SST, remove the center differential case tapered roller bearing RH outer race, transfer ring gear mounting case washer No.2 and right bearing retainer oil seal No.2 from the transfer RH bearing retainer sub-assy.

SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer sub-assy.

31. REMOVE SIDE GEAR SHAFT HOLDER BEARING

REMOVE SIDE GEAR SHAFT HOLDER BEARING


(a) Using snap ring pliers, remove the side gear shaft holder hole snap ring.

(b) Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assy.

32. REMOVE TRANSFER RING GEAR MOUNTING CASE

REMOVE TRANSFER RING GEAR MOUNTING CASE


(a) Remove the transfer ring gear mounting case from the transfer case.

33. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


(a) LH side: Using SST, remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.

SST 09950- 40011 (09951- 04010, 09952- 04010, 09953- 04020, 09954- 04010, 09955- 04061, 09957- 04010, 09958- 04011), 09950- 60010 (09951-00420)

NOTICE: Apply grease to the screw thread and tip of the SST before use.

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


HINT: When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.

SST 09950- 00020, 09950- 00030, 09950- 60010 (09951-00430)

NOTICE: Apply grease to the screw thread and tip of the SST before use.

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


(b) RH side: Using SST, remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.

SST 09950- 40011 (09951- 04010, 09952- 04010, 09953- 04020, 09954- 04010, 09955- 04061, 09957- 04010, 09958- 04011), 09950- 60010 (09951-00360)

NOTICE: Apply grease to the screw thread and tip of the SST before use.

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


HINT: When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.

SST 09950- 00020, 09950- 00030, 09950- 60010 (09951-00360)

NOTICE: Apply grease to the screw thread and tip of the SST before use.

34. REMOVE RING GEAR

REMOVE RING GEAR


(a) Put matchmarks on the transfer ring gear mounting case and the ring gear.

(b) Remove the 12 bolts.

REMOVE RING GEAR


(c) Using a plastic hammer, remove the ring gear by tapping around its periphery.

NOTICE: Do not damage the teeth of the ring gear.

HINT: If the runout is too large, replace the transfer ring rear mounting case.

35. INSPECT RUNOUT OF TRANSFER RING GEAR MOUNTING CASE

INSPECT RUNOUT OF TRANSFER RING GEAR MOUNTING CASE


(a) Using a dial indicator, check the transfer ring gear mounting case runout.

Maximum runout: 0.03 mm (0.0012 in.)

HINT: If the runout is too large, replace the center differential control coupling assy or transfer ring gear mounting case.

36. REMOVE DRIVEN PINION

REMOVE DRIVEN PINION


(a) Using SST and a hammer, unstake the transfer gear nut.

SST 09930-00010

REMOVE DRIVEN PINION


(b) Using SST, remove the transfer gear nut.

SST 09326-2001 1, 09556-16030

REMOVE DRIVEN PINION


(c) Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer.

NOTICE:

37. REMOVE TRANSFER DRIVEN PINION FRONT BEARING

REMOVE TRANSFER DRIVEN PINION FRONT BEARING


(a) Using SST and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.

SST 09950-00020

38. REMOVE TRANSFER DRIVEN PINION FRONT BEARING

REMOVE TRANSFER DRIVEN PINION FRONT BEARING


(a) Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 points to remove it from the transfer case.

39. REMOVE TRANSFER OUTPUT WASHER

(a) Remove the ring gear mounting case plate washer from the transfer case.

40. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


(a) Using a brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.

41. REMOVE RING GEAR MOUNTING CASE PLATE WASHER

(a) Remove the transfer output washer from the transfer case.

42. REMOVE TRANSFER DRIVEN PINION REAR BEARING

REMOVE TRANSFER DRIVEN PINION REAR BEARING


(a) Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.

43. INSTALL TRANSFER DRIVEN PINION REAR BEARING

INSTALL TRANSFER DRIVEN PINION REAR BEARING


(a) Using SST and a press, install the transfer driven pinion rear bearing outer race to the transfer case.

SST 09950- 60010 (09951- 00620), 09950- 70010 (09951-07150)

NOTICE: Place something like wooden blocks under the case to keep its level.

44. INSTALL TRANSFER OUTPUT WASHER

(a) Install the transfer output washer to the transfer case.

HINT: Reuse the washer.

45. INSTALL TRANSFER DRIVEN PINION FRONT BEARING

INSTALL TRANSFER DRIVEN PINION FRONT BEARING


(a) Install the transfer driven pinion front bearing outer race to the transfer case with SST, bolt and nut.

SST 09950- 60020 (09951- 00750, 09951- 00770, 09951-00810), 09316-60011 (09316-00061)

46. INSTALL RING GEAR MOUNTING CASE PLATE WASHER

 INSTALL RING GEAR MOUNTING CASE PLATE WASHER


(a) Install the ring gear mounting case plate washer to the transfer case.

HINT: Reuse the washer.

47. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

(a) Using SST and a press, install the center differential case tapered roller bearing LH outer race to the transfer case.

SST 09950- 70010 (09951- 07200), 09316- 60011 (09316-00021)

48. INSTALL TRANSFER DRIVEN PINION FRONT BEARING

 INSTALL TRANSFER DRIVEN PINION FRONT BEARING


(a) Using SST and a press, install the transfer driven pinion front bearing inner race to the driven pinion.

SST 09316-6001 1 (09316-00041)

49. INSTALL DRIVEN PINION

INSTALL DRIVEN PINION


(a) Install the driven pinion to the transfer case.

INSTALL DRIVEN PINION


(b) Install a new transfer pinion bearing spacer and a new transfer driven pinion rear bearing inner race to the driven pinion.

INSTALL DRIVEN PINION


(c) Using SST, tighten a new transfer gear nut (at a standard torque.)

SST 09326-2001 1, 09556-16030

Torque: 277 to 378 NVm (2,820 to 3,855 kgfVcm, 204 to 279 ftVlbf)

NOTICE: Do not stake the transfer gear nut.

HINT: Use a torque wrench with a fulcrum length of 750 mm (29.53 in.)

50. INSPECT AND ADJUST DRIVEN PINION PRELOAD

INSPECT AND ADJUST DRIVEN PINION PRELOAD


(a) Using SST and a torque wrench, measure the initial torque of the driven pinion.

Preload (at starting): New bearing: 1.1 to 1.6 NVm (11 to 16 kgfVcm, 9.7 to 14.2 in.Vlbf) Used bearing: 0.9 to 1.4 NVm (9 to 14 kgfVcm, 8.0 to 12.4 in.Vlbf)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.) NOTICE: Measure preload after rotating the bearing both clockwise and counterclockwise to make it fit.

(b) If the preload is too large, replace the transfer pinion bearing spacer with a new one.

(c) If the preload is too small, repeatedly adjust the preload by tightening the transfer gear nut 5 to 10 degrees at a time until the standard value is obtained.

(d) If the preload is insufficient, even though the tightening torque of the transfer gear nut exceeds the maximum of the standard value, loosen the transfer gear nut and apply gear oil SAE 90 (GL-5) to the transfer gear nut and the screw thread and the base of the driven pinion. And then repeat the preceding operation. If the tightening torque is smaller than the standard, replace the transfer pinion bearing spacer with a new one and adjust it.

SST 09326-2001 1, 09556-16030

Torque: 378 NVm (3,855 kgfVcm, 279 ftVlbf)

51. INSTALL RING GEAR

INSTALL RING GEAR


(a) Completely remove grease and moisture on the contact surfaces of the ring gear and the transfer ring gear mounting case.

(b) Heat the ring gear in boiling water from 90 to 100 C (194 to 212 F).

(c) Carefully take the ring gear out of the boiling water.

 INSTALL RING GEAR


(d) Align the matchmarks on the ring gear and transfer ring gear mounting case and quickly assemble them.

(e) Tighten the12 bolts.

Torque: 78 NVm (790 kgfVcm, 57 ftVlbf)

NOTICE:

52. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


(a) RH side: Using SST and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case.

SST 09506-35010, 09950-60010 (09951-00430)

NOTICE: When replacing the inner race, replace it together with the outer race.

INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


(b) LH side: Using SST and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case.

SST 09223-00010

NOTICE: When replacing the inner race, replace it together with the outer race.

53. INSTALL TRANSFER RING GEAR MOUNTING CASE

INSTALL TRANSFER RING GEAR MOUNTING CASE


(a) Install the transfer ring gear mounting case to the transfer case.

NOTICE: Damage to the spline, the bearing's rotating surface and gear face may cause a decrease in their strength. Care should be taken when installing them.

54. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2

(a) Install the transfer ring gear mounting case washer No.2 to the transfer RH bearing retainer sub-assy.

HINT: Reuse the washer.

55. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


(a) Using SST and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer sub-assy.

SST 09950- 60010 (09951- 00620), 09950- 70010 (09951-07150)

56. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY


(a) Place the transfer with the face where the transfer RH bearing retainer sub-assy is to be installed facing up.

(b) Center-align the transfer ring gear mounting case and the transfer case.

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY


(c) Insert the SST into the transfer RH bearing retainer subassy.

SST 09387-00090

NOTICE: Insert SST straight in order not to damage the oil seal lip.

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY


(d) Insert the transfer RH bearing retainer sub-assy together with the SST into the transfer case.

NOTICE: Interference between the case and retainer, and between the transfer ring gear mounting case and SST should be carefully avoided.

HINT: If the retainer cannot be inserted, tap it in with a plastic hammer.

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY


(e) After inserting the transfer RH bearing retainer sub-assy into the transfer case, remove the SST.

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY


(f) Tighten the 7 bolts.

Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)

57. INSPECT BACKLASH

INSPECT BACKLASH


(a) Set the dial indicator perpendicular to the ring gear face, fix the driven pinion, and check backlash by moving the ring gear.

Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.)

NOTICE: Measure it at 3 points or more on the ring gear periphery.

(b) If the measured value is out of standard, select a proper washer for the center differential case tapered roller bearing on the LH side from the table below and install it to obtain the standard value.

INSPECT BACKLASH


HINT: When the backlash is larger or smaller than the standard, select a thinner or thicker washer respectively.

INSPECT BACKLASH


(c) Ring gear mounting case plate washer location is shown in the illustration.

58. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION


(a) Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate it several times.

NOTICE: Check the tooth contact on the ring gear at 4 places or more.

(b) Observe the pattern shown by red lead primer.

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION


(c) In case of poor tooth contact, select a washer for the driven pinion bearing front side from the following table and replace it.

NOTICE: If the washer thickness is changed, the backlash will be also changed.

INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION


INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION


(d) The location of the transfer output washer for tooth contact adjustment is shown in the illustration.

59. ADJUST TOTAL PRELOAD

ADJUST TOTAL PRELOAD


(a) Using SST and a torque wrench, measure the initial torque with the driven pinion being contact with the ring gear face.

SST 09326-2001 1

Torque: New bearing: Driven pinion preload +0.2 to 0.4 NVm (+2.3 to 3.9 kgfVcm, 1.8 to 3.5 in.Vlbf) Used bearing: Driven pinion preload +0.15 to 0.30 NVm (+1.6 to 3.1 kgfVcm, 1.3 to 2.7 in.Vlbf)

NOTICE: Before measurement, rotate the bearing in both directions several times to make it fit.

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).

(b) If the value is out of standard range, select the washer for the center differential case tapered roller bearing RH side from the following table and replace it.

ADJUST TOTAL PRELOAD


ADJUST TOTAL PRELOAD


(c) The location of the transfer ring gear mounting case washer No.2 for preload adjustment is shown in the illustration.

ADJUST TOTAL PRELOAD


(d) Using a chisel, stake the transfer gear nut.

60. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY

REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY


(a) Remove the 7 bolts from the transfer RH bearing retainer sub-assy .

REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY


(b) Using a screwdriver and a hammer, make a opening between the transfer RH bearing retainer sub-assy and the transfer case.

NOTICE: Be careful not to damage the transfer RH bearing retainer sub-assy and the transfer case.

REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY


(c) Using SST, remove the transfer RH bearing retainer subassy from the transfer case.

SST 09520-10021

61. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

 

(a) Fix the transfer RH bearing retainer sub-assy in a vise.z (b) Using SST, remove the center differential case tapered roller bearing RH outer race and transfer ring gear mounting case washer No.2 from the transfer RH bearing retainer sub-assy.

SST 09308-00010

62. INSTALL SIDE GEAR SHAFT HOLDER BEARING

INSTALL SIDE GEAR SHAFT HOLDER BEARING


(a) Install the side gear shaft holder bearing to the transfer RH bearing retainer sub-assy.

(b) Using snap ring pliers, install the side gear shaft holder hole snap ring.

HINT: Check that the side gear shaft holder hole snap ring fits in the groove of the transfer RH bearing retainer sub-assy.

63. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL

INSTALL TRANSFER RH BEARING RETAINER OIL SEAL


(a) Using SST and a press, install the transfer RH bearing retainer oil seal No.2 to the transfer RH bearing retainer sub-assy .

SST 09950- 60010 (09951- 00350, 09951- 00560, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Carefully press-fit so that the oil seal will not be tilted.

(b) Apply small amount of MP grease No.2 to the oil seal lip.

64. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2

INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2


(a) Install the selected transfer ring gear mounting washer No.2 to the transfer RH bearing retainer subassy.

65. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

 INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


(a) Using SST and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer sub-assy.

SST 09950- 60010 (09951- 00620), 09950- 70010 (09951-07150)

66. INSTALL O-RING

INSTALL O-RING


(a) Coat 2 new O-rings with hypoid gear oil.

(b) Install the 2 O-rings to the transfer RH bearing retainer sub-assy .

NOTICE: Be careful not to twist the O-ring but to fit it properly in the retainer's groove.

67. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY


(a) Place the transfer with the surface where the transfer RH bearing retainer sub-assy is facing up.

(b) Align the centers of the transfer ring gear mounting case and the transfer case.

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY


(c) Insert SST into the transfer RH bearing retainer subassy.

SST 09387-00090

NOTICE: Insert SST straight in order not to damage the oil seal.

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY


(d) Insert the transfer RH bearing retainer sub-assy together with SST into the transfer case.

NOTICE:

HINT: If the retainer cannot be inserted into the case, tap it in with a plastic hammer.

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY


(e) After inserting the transfer RH bearing retainer sub-assy into the transfer case, remove the SST.

INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY


(f) Tighten the 7 bolts.

Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)

68. INSPECT TOTAL PRELOAD

INSPECT TOTAL PRELOAD


(a) Using SST and a torque wrench, measure the initial torque with the driven pinion being in contact with the ring gear face.

SST 09326-2001 1

Torque: New bearing: Driven pinion preload +0.2 to 0.4 NVm (+2.3 to 3.9 kgfVcm, 1.8 to 3.5 in.Vlbf) Used bearing: Driven pinion preload +0.15 to 0.30 NVm (+1.6 to 3.1 kgfVcm, +1.3 to 2.7 in.Vlbf)

HINT:

69. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL

 INSTALL TRANSFER RH BEARING RETAINER OIL SEAL


(a) Using SST, install the transfer RH bearing retainer oil seal to the transfer RH bearing retainer sub-assy to the position as shown in the illustration.

SST 09223-4601 1

NOTICE: Install the oil seal carefully so that it will not be tilted.

(b) Apply MP grease to the oil seal lip.

70. INSTALL TRANSFER CASE OIL SEAL

 INSTALL TRANSFER CASE OIL SEAL


(a) Using SST, install the transfer case oil seal to the transfer case at the position as shown as in the illustration.

SST 09387-00010, 09950-70010 (09951-07150)

NOTICE: Install the oil seal carefully so that it will not be tilted.

(b) Apply small amount of MP grease to the oil seal lip.

71. INSTALL CTR DIFFERENTIAL LOCK SLEEVE

INSTALL CTR DIFFERENTIAL LOCK SLEEVE


(a) Coat a new O-ring with hypoid gear oil.

(b) Install the O-ring to the CTR differential lock sleeve.

NOTICE: Be careful not to twist the O-ring but to fit it properly in the retainer's groove.

INSTALL CTR DIFFERENTIAL LOCK SLEEVE


(c) Using SST, install the CTR differential lock sleeve to the transfer case.

SST 09950- 60010 (09951- 00610), 09950- 70010 (09951-07150)

INSTALL CTR DIFFERENTIAL LOCK SLEEVE


(d) Using snap ring pliers, install the shaft snap ring.

NOTICE: Check that the snap ring is fitted in the groove of the ring gear mounting case.

72. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL


(a) Using SST, install the transfer extension housing type T oil seal to the transfer extension housing at the position as shown in the illustration.

SST 09950- 60010 (09951- 00380, 09951- 00580, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Install the oil seal carefully so that it will not be tilted.

(b) Apply small amount of MP grease No.2 to the oil seal lip.

73. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR

INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR


(a) Using SST and a press, install a new transfer extension housing dust deflector to the transfer extension housing sub-assy .

SST 09950- 60020 (09951- 00710), 09950- 70010 (09951-07150)

74. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSY

INSTALL TRANSFER EXTENSION HOUSING SUB-ASSY


(a) Apply sealant 1281 to the transfer extension housing sub-assy in continuous beaded form of 1.2 mm diameter as shown in the illustration.

NOTICE:

INSTALL TRANSFER EXTENSION HOUSING SUB-ASSY


(b) Install the transfer extension housing sub-assy to the transfer case with the 4 bolts.

Torque: 26 NVm (260 kgfVcm, 19 ftVlbf)

(c) Remove the transfer assy from the overhaul attachment

75. INSTALL TRANSFER & TRANSAXLE SETTING STUD BOLT

INSTALL TRANSFER & TRANSAXLE SETTING STUD BOLT


(a) Install the 4 transfer & transaxle setting stud bolts to the parts of the transfer case as shown in the illustration.

Torque: 39 NVm (400 kgfVcm, 30 ftVlbf)

NOTICE: Install the sealant-coated side of the transfer & transaxle stud bolt to the transfer case.

76. INSTALL TRANSFER CASE STRAIGHT PIN

 INSTALL TRANSFER CASE STRAIGHT PIN


(a) Using a plastic hammer, install the 4 transfer case straight pins to the transfer case as shown in the illustration.

77. INSTALL TRANSFER DYNAMIC DAMPER

INSTALL TRANSFER DYNAMIC DAMPER


(a) Install the transfer dynamic damper to the transfer extension housing sub-assy with the 3 bolts.

Torque: 26 NVm (260 kgfVcm, 19 ftVlbf)

78. INSTALL BREATHER OIL DEFLECTOR

INSTALL BREATHER OIL DEFLECTOR


(a) Install the breather oil deflector to the transfer case cover No.1 with the bolt.

Torque: 6.5 NVm (66 kgfVcm, 57 in.Vlbf)

NOTICE: Be careful of the direction of the deflector's fold.

79. INSTALL TRANSFER CASE COVER NO.1

INSTALL TRANSFER CASE COVER NO.1


(a) Apply sealant 1281 to the transfer case cover No.1 in a continuous bead of 1.2 mm diameter as shown in the illustration.

NOTICE:

INSTALL TRANSFER CASE COVER NO.1


(b) Install the transfer case cover No.1 to the transfer case with the 8 bolts.

Torque: 20 NVm (200 kgfVcm, 14 ftVlbf)

80. TRANSFER CASE BREATHER PLUG

TRANSFER CASE BREATHER PLUG


(a) Using SST and a hammer, install the transfer case breather plug to the transfer case cover No.1.

SST 09612-10061)

81. INSTALL TRANSFER COVER GASKET

 INSTALL TRANSFER COVER GASKET


(a) Install a new transfer cover gasket to the transfer case.

82. INSTALL TRANSFER ASSY

INSTALL TRANSFER ASSY


(a) Apply sealant 1281 to the transaxle assy and the transfer assy in continuous beaded form of 1.2 mm diameter as shown in the illustration.

NOTICE:

INSTALL TRANSFER ASSY


(b) Install the transfer assy to the transaxle assy with the 2 bolts and 6 nuts.

Torque: 69 NVm (700 kgfVcm, 51 ftVlbf)

NOTICE:

83. INSTALL ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE)

(a) Install the engine mounting bracket RR with the 3 bolts.

Torque: 64 NVm (652 kgfVcm, 47 ftVlbf)

84. INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE)

INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE)


(a) Install the stiffener plate RH with the 5 bolts.

Torque: 34 NVm (350 kgfVcm, 25 ftVlbf)

85. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE) (SEE PAGE 40-20 )

86. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 )

87. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 )

88. INSTALL TRANSFER DRAIN PLUG

INSTALL TRANSFER DRAIN PLUG


(a) Install the transfer drain plug with a new drain gasket.

Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)

89. INSTALL TRANSFER CASE NO.2 PLUG

(a) Install the transfer case No.2 plug with a new gasket No.2.

Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)

90. INSTALL TRANSFER CASE NO.1 PLUG

(a) Add oil up to 0 to 5 mm below the lower side of the plug hole.

Oil quantity: 0.9 L (0.95 US qts, 0.79 lmp. qts)

HINT: When adding oil, pour it slowly.

(b) Install the transfer case No.1 plug with a new gasket No.1.

Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)

Transfer extension housing type T oil seal (4WD)
REPLACEMENT 1. REMOVE EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 2. REMOVE EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) 3. REMOVE TRANSFER CASE NO.1 PLUG 4. REMOVE TRANSFER ...

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