Part 2
LF1A TRANSFER: TRANSFER ASSEMBLY: REASSEMBLY
18. INSTALL TRANSFER OIL SEAL RING
(a) Install the oil seal ring to the input shaft.
NOTICE:
Do not excessively widen the oil seal ring.
19. INSTALL TRANSFER INPUT SHAFT
(a) Install the input shaft to the drive gear.
20. INSTALL TRANSFER FRONT DRIVE GEAR PIN
(a) Install the pin to the front transfer case.
21. INSTALL TRANSFER FRONT DRIVE GEAR ASSEMBLY
(a) Install the drive gear and input shaft to the front transfer case.
22. INSTALL TRANSFER COUNTER GEAR ASSEMBLY
(a) Install the counter gear to the front transfer case.
23. INSTALL TRANSFER OIL PUMP DRIVE SHAFT
(a) Install the drive shaft to the front transfer case.
24. INSTALL TRANSFER IDLER GEAR ASSEMBLY
(a) Install the idler gear to the front transfer case.
25. INSTALL REAR TRANSFER CASE
(a) Apply seal packing to the rear transfer case as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
Seal packing diameter:
1.2 mm (0.0472 in.)
NOTICE:
* Remove any oil from the contact surfaces.
* Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG material) must be removed and reapplied.
(b) Install the rear transfer case with the 7 bolts to the front transfer case.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
26. INSTALL TRANSFER INPUT GEAR STOPPER
(a) Install the gear stopper to the input shaft.
27. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING
(a) Using a snap ring expander, install the snap ring to the input shaft.
28. INSTALL BREATHER OIL DEFLECTOR
(a) Install the oil deflector with the 2 bolts to the rear transfer case.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)
29. INSTALL TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING
(a) Using SST and a press, install a new bearing (inner race) to the differential case.
SST : 09316-60011
09316-00011
09316-00021
30. INSTALL NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Install the differential case to the rear transfer case.
31. INSTALL TRANSFER OUTPUT SHAFT SHIM
(a) Install the output shaft shim to the differential case.
32. INSTALL NO. 2 TRANSFER THRUST BEARING RACE
(a) Install the bearing race to the output shaft shim.
33. INSTALL DIFFERENTIAL CASE NEEDLE ROLLER BEARING
(a) Install the needle roller bearing to the bearing race.
34. INSTALL TRANSFER OUTPUT SHAFT WASHER
(a) Install the 2 shaft washers to the differential case.
35. INSTALL NO. 1 TRANSFER THRUST BEARING RACE
(a) Install the bearing race to the needle roller bearing.
36. ADJUST TRANSFER OUTPUT SHAFT SHIM
(a) Using a vernier caliper and precision straightedge, measure dimension A between the top surface of the extension housing [*1] and the surface which contacts the No. 1 thrust bearing race [*2].
NOTICE:
Do not add the thickness of the precision straightedge.
(b) Using a vernier caliper and precision straightedge, measure dimension B between the surface of the No. 1 thrust bearing race [*1] and the surface of the rear transfer case extension housing [*2].
NOTICE:
Do not add the thickness of the precision straightedge.
(c) Using the formula below, calculate the thickness of the transfer output shim and select an appropriate shim from the table.
Transfer output shim thickness:
Dimension A - Dimension B
Transfer Output Shim Thickness:
37. INSTALL TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING
(a) Using SST and a press, install a new bearing (outer race) to the extension housing.
SST : 09950-60010
09951-00600
SST : 09950-70010
09951-07100
38. INSTALL NO. 1 DIFFERENTIAL CASE HOLE SNAP RING
(a) Using needle-nose pliers, install the snap ring to the extension housing.
39. INSTALL TRANSFER EXTENSION HOUSING OIL SEAL
(a) Using SST and a hammer, install a new oil seal to the extension housing.
SST : 09726-36010
SST : 09950-70010
09951-07100
Standard oil seal depth:
12 to 12.5 mm (0.473 to 0.492 in.)
NOTICE:
* Do not tap in the oil seal at an angle.
* Do not tap in the oil seal excessively.
* Be careful of the positions of the straight pins when performing this procedure.
(b) Coat the lip of the outer shaft lever oil seal with MP grease.
40. INSTALL TRANSFER EXTENSION HOUSING
(a) Apply seal packing to the transfer extension housing as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
Seal packing diameter:
1.2 mm (0.0472 in.)
NOTICE:
* Remove any oil from the contact surfaces.
* Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG material) must be removed and reapplied.
(b) Install the transfer extension housing with the 11 bolts to the rear transfer case.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
41. INSTALL DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
(a) Install the companion flange to the output shaft.
(b) Install a new nut to the output shaft.
(c) Using SST, hold the companion flange in place.
SST : 09330-00021
SST : 09950-30012
09955-03040
(d) Using a 30 mm socket wrench, tighten the transfer output shaft nut.
Torque : 142 Nm (1448 kgf-cm, 105 ft-lbf)
(e) Using a chisel and hammer, stake the transfer output shaft nut.
42. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
(a) Install the companion flange to the transfer assembly, and then using SST, hold the companion flange in place.
SST : 09213-58013
SST : 09330-00021
HINT
Use bolts of size M8 x P1.25 with a length of approximately 55 mm (2.16 in.) or equivalent to secure the companion flange.
(b) Tighten the companion flange bolt.
Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)
43. INSTALL NO. 2 TRANSFER CASE PLUG
(a) Using a 17 mm straight hexagon wrench, install a new gasket and the case plug to the rear transfer case.
Torque : 98 Nm (1000 kgf-cm, 72 ft-lbf)
44. INSTALL TRANSFER CASE BREATHER PLUG
(a) Using SST and a hammer, install the breather plug to the front transfer case.
SST : 09350-30020
09350-07110
45. INSTALL TRANSFER DRAIN PLUG
(a) Using a 10 mm hexagon socket wrench, install a new gasket and the drain plug to the rear transfer case.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
46. INSTALL FILLER PLUG
(a) Using a 10 mm hexagon socket wrench, install a new gasket and the filler plug to the rear transfer case.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
47. INSTALL TRANSFER CASE PLUG
(a) Using a 6 mm hexagon socket wrench, install 2 new O-rings and the 2 case plugs to the front transfer case.
Torque : 19 Nm (190 kgf-cm, 14 ft-lbf)
48. INSTALL DYNAMIC DAMPER
(a) Install the damper and 2 washers with the bolt to the rear transfer case.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)