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Home >> Lexus Truck >> 1998 >> LX 470 V8-4.7L (2UZ-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Transfer Case >> Service and Repair >> Part 2

Part 2

IDLER GEAR





Components

Disassembly
1. INSPECT IDLER LOW GEAR RADIAL AND THRUST CLEARANCE





a. Using a feeler gauge, measure the idler low gear thrust clearance.

Standard clearance:
0.125 - 0.275 mm (0.0049 - 0.0108 inch)
Maximum clearance:
0.275 mm (0.0108 inch)





b. Using a dial indicator, measure the idler low gear radial clearance.

Standard clearance:
0.015 - 0.068 mm (0.0006 - 0.0027 inch)
Maximum clearance:
0.068 mm (0.0027 inch)





2. REMOVE FRONT TAPER ROLLER BEARING
Using SST, remove the front taper roller bearing.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04060, 09957-04010, 09958-04010), 09950-60010 (09951-00330)

NOTICE: Set the claw of SST to the bearing inner race securely.





3. REMOVE REAR TAPER ROLLER BEARING
Using SST, a press and socket wrench, remove the rear taper roller bearing.
SST 09950-00020

NOTICE: Set the claw of SST to the bearing inner race securely.





4. REMOVE IDLER LOW GEAR AND NEEDLE ROLLER BEARING FROM IDLER GEAR





5. REMOVE HIGH AND LOW CLUTCH SLEEVE FROM IDLER GEAR

Inspection





1. INSPECT IDLER GEAR
Using a micrometer, measure the idler gear diameter.

Standard diameter:
38.48 - 38.50 mm (1.5149 - 1.5157 inch)
Maximum diameter:
38.50 mm (1.5157 inch)





2. INSPECT IDLER LOW GEAR
Using a cylinder gauge, measure the idler low gear diameter.

Standard diameter:
45.52 - 45.54 mm (1.7922 - 1.7930 inch)
Maximum diameter:
45.54 mm (1.7930 inch)

Reassembly

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.





1. INSTALL FRONT TAPER ROLLER BEARING
Using SST and a press, install the front taper roller bearing. SST 09316-60011 (09316-00011, 09316-00031)





2. INSTALL HIGH AND LOW CLUTCH SLEEVE

HINT: Make sure to install the high and low clutch sleeve in the correct direction.





3. INSTALL NEEDLE ROLLER BEARING AND IDLER LOW GEAR TO IDLER GEAR
a. Apply gear oil to the needle roller bearing.
b. Install the needle roller bearing and idler low gear.





4. INSTALL REAR TAPER ROLLER BEARING
Using SST and a press, install the rear taper roller bearing.
SST 09316-60011 (09316-00011, 09316-00071)
5. INSPECT IDLER LOW GEAR RADIAL AND THRUST CLEARANCE

CENTER DIFFERENTIAL





Components

Disassembly
1. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE





a. Using a feeler gauge, measure the high speed output gear thrust clearance.

Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Maximum clearance:
0.25 mm (0.0098 inch)






b. Using a dial indicator, measure the high speed output gear radial clearance.

Standard clearance:
0.035 - 0.091 mm (0.0014 - 0.0036 inch)
Maximum clearance:
0.091 mm (0.0036 inch)





2. REMOVE FRONT DRIVE GEAR PIECE
a. Using a snap ring expander, remove the snap ring.
b. Using SST and a press, remove the front drive gear piece.
SST 09950-00020,09950-60010(09951-00320)

NOTICE: Be careful not to drop the center differential assembly.





3. REMOVE FRONT TAPER ROLLER BEARING
Using SST and a press, remove the front taper roller bearing.
SST 09950-00020

NOTICE: Set the claw of SST to the bearing inner race securely.





4. REMOVE HIGH SPEED OUTPUT GEAR
5. REMOVE NEEDLE ROLLER BEARING





6. REMOVE HIGH AND LOW CLUTCH SLEEVE





7. REMOVE HIGH SPEED OUTPUT GEAR BUSHING AND CLUTCH HUB
a. Using SST, remove the high speed output gear bushing and clutch hub.
SST 09950-00020,09950-00030,09950-60010 (09951-00320)
b. Using a magnetic finger, remove the straight pin from the differential front case.





8. REMOVE REAR TAPER ROLLER BEARING
Using SST and a press, remove the rear taper roller bearing.
SST 09950-00020, 09950-60010 (09951-00320)

NOTICE: Set the claw of SST to the bearing inner race securely.





9. REMOVE DIFFERENTIAL REAR CASE
Remove the 12 bolts and differential rear case.





10. REMOVE REAR SIDE GEAR AND THRUST WASHER
11. REMOVE PINION SHAFT, PINION GEAR AND THRUST WASHER





a. Remove the straight pin from the pinion shaft.





b. Remove the pinion shaft, 2 pinion gears and thrust washers.





c. Remove the front side gear and thrust washer.





12. REMOVE LOW GEAR
Using a plastic hammer, tap and remove the low gear.

NOTICE: Be careful not to damage the low gear.





13. REMOVE NEEDLE ROLLER BEARING
a. Using a screwdriver, remove the snap ring.
b. Using SST and a hammer, remove the needle roller bearing from the differential rear case.
SST 09223-00010, 09950-60010 (09951-00400), 09950-70010(09951-07150)

Reassembly

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.





1. INSTALL NEEDLE ROLLER BEARING
a. Using SST and a press, install the needle roller bearing to the differential rear case.
SST 09612-24014 (09612-10050)

HINT: Install the bearing to the differential rear case, taking care that its stamped side comes in contact with SST.

b. Install the snap ring.





2. INSTALL LOW GEAR
a. Clean the contact surface of the differential case.
b. Heat the low gear in boiling water.
c. Carefully remove the low gear from the water.
d. After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case.
3. INSTALL PINION SHAFT, PINION GEAR AND THRUST WASHER





a. Install the front side gear and thrust washer to the differential front case.





b. Install the pinion shaft, 2 pinion gears and thrust washers to the differential front case.





c. Using a dial indicator, measure the front case backlash.

HINT: Push the pinion shaft.

Minimum backlash: 0.05 mm (0.0020 inch)





If the backlash is not within the specification, replace the thrust washer with one of the correct size and reinstall the thrust washer.
d. In the same way, measure the rear case backlash.
4. INSTALL STRAIGHT PIN TO PINION SHAFT
5. INSTALL REAR SIDE GEAR AND THRUST WASHER
6. INSTALL DIFFERENTIAL REAR CASE
Install the differential rear case and 12 set bolts.
7. TORQUE REAR CASE SET BOLT





a. Torque the 12 rear case set bolts.

Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.)

b. Turn the pinion gear.
c. Loosen the 12 rear case set bolts.
d. Torque the 12 rear case set bolts.

Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.)





8. INSTALL REAR TAPER ROLLER BEARING
Using SST and a press, install the rear taper roller bearing.
SST 09316-12010





9. INSTALL CLUTCH HUB
Using SST and a press, install the clutch hub.
SST 09316-12010, 09316-60011 (09316-00011)





10. INSTALL HIGH SPEED OUTPUT GEAR BUSHING
a. Apply MP grease to the straight pinch
b. Install the straight pin, as shown.





c. Using SST and a press, install the high speed output gear bushing.
SST 09316-12010, 09316-60011 (09316-00011)

NOTICE: Before pressing, align the holes on the bushing and shaft so that the pin on the shaft is aligned with the cut-out of the bushing.





11. INSTALL HIGH AND LOW CLUTCH SLEEVE

HINT: Make sure to install the high and low clutch sleeve in the correct direction.

12. INSTALL HIGH SPEED OUTPUT GEAR AND NEEDLE ROLLER BEARING
a. Apply gear oil to the needle roller bearing.
b. Install the high speed output gear and needle roller bearing.





13. INSTALL FRONT TAPER ROLLER BEARING
Using SST and a press, install the front taper roller bearing.
SST 09316-12010, 09316-60011 (09316-00011)





14. INSTALL FRONT DRIVE GEAR PIECE
Using SST and a press, install the front drive gear piece.
SST 09316-12010, 09316-60011 (09316-00011)





15. INSTALL SNAP RING





a. Select a snap ring that will allow the minimum axial play.
b. Using a snap ring expander, install a new snap ring.
16. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE

FRONT EXTENSION HOUSING





Components

Disassembly





1. REMOVE DRIVE CLUTCH HUB
a. Using a snap ring expander, remove the snap ring.
b. Using SST, remove the drive clutch hub.
SST 09950-40011(09951-04020,09952-04010, 09953-04030,09954-04020,09955-04020, 09957-04010,09958-04010)





2. REMOVE FRONT OUTPUT SHAFT
Using a plastic hammer, drive out the front output shaft.
3. REMOVE DUST DEFLECTOR





a. Using SST, remove the dust deflector.
SST 09950-40011(09951-04020,09952-04010, 09953-04030,09954-04010,09955-04050, 09957-04010,09958-04010)





b. Using a screwdriver and hammer, tap the dust deflector and remove it from the extension housing.





4. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal from the front extension housing.
5. REMOVE BALL BEARING





a. Using a screwdriver, remove the snap ring.





b. Using SST and a press, remove the ball bearing.
SST 09316-60011 (09316-00011, 09316-00071)

Reassembly

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL DUST DEFLECTOR





a. Using a plastic hammer, install the dust deflector to the front extension housing.





b. Using SST and a press, install a new dust deflector to the front output shaft.
SST 09316-20011,09316-60011(09316-00011)
2. INSTALL BALL BEARING





a. Using SST and a press, install the ball bearing to the front extension housing.
SST 09316-60011 (09316-00011, 09316-00031)





b. Select a snap ring that will allow the minimum axial play.





c. Using a screwdriver, install a new snap ring.
3. INSTALL OIL SEAL
a. Apply Multipurpose (MP) grease to the lip of a new oil seal.





b. Using SST and a hammer, drive in a new oil seal to the front extension housing.
SST 09316-60011(09316-00011,09316-00061)
4. INSTALL FRONT OUTPUT SHAFT AND DRIVE CLUTCH HUB





a. Using SST and a press, install the front output shaft and drive clutch hub. SST 09316-20011, 09316-60011 (09316-00011, 09316-00041, 09316-00071)





b. Select a snap ring that will allow the minimum axial play.





c. Using a snap ring expander, install a new snap ring.

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