Reassembly
LF1A TRANSFER: TRANSFER ASSEMBLY: REASSEMBLY
1. INSTALL TRANSFER FRONT DRIVE GEAR CYLINDRICAL ROLLER BEARING (for Rear Transfer Case Side)
(a) Using SST and a press, install a new bearing to the rear transfer case.
SST : 09950-60020
09951-00710
SST : 09950-70010
09951-07100
(b) Using needle-nose pliers, install the snap ring to the rear transfer case.
2. INSTALL TRANSFER FRONT DRIVE GEAR BEARING
(a) Install the bearing and bearing race to the front transfer case.
3. INSTALL TRANSFER FRONT DRIVE GEAR CYLINDRICAL ROLLER BEARING (for Front Transfer Case Side)
(a) Using SST and a press, install a new bearing (outer race) to the front transfer case.
SST : 09527-17011
SST : 09951-01000
SST : 09950-70010
09951-07150
4. INSTALL TRANSFER FRONT CASE OIL SEAL
(a) Using SST and a hammer, install a new oil seal to the front transfer case.
SST : 09223-15020
Standard depth:
1.0 to 1.5 mm (0.0394 to 0.0591 in.)
NOTICE:
* Do not tap in the oil seal at an angle.
* Do not tap in the oil seal excessively.
(b) Coat the lip of the outer shaft lever oil seal with MP grease.
5. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
(a) Using SST and a hammer, install a new oil seal to the front transfer case.
SST : 09316-60011
09316-00011
Standard depth:
2.5 to 3.0 mm (0.0984 to 0.118 in.)
NOTICE:
* Do not tap in the oil seal at an angle.
* Do not tap in the oil seal excessively.
(b) Coat the lip of the outer shaft lever oil seal with MP grease.
6. INSTALL FORWARD CLUTCH DRAM OIL SEAL RING
(a) Install the oil seal ring to the sleeve.
7. INSTALL TRANSFER COUNTER GEAR BEARING (for Front Transfer Case Side)
(a) Using SST and a press, install a new bearing (outer race) to the front transfer case.
SST : 09950-60010
09951-00580
09951-00630
09952-06010
SST : 09950-60020
09951-00750
09951-00790
09952-06010
SST : 09950-70010
09951-07100
8. INSTALL TRANSFER COUNTER GEAR BEARING
(a) for Front Transfer Case Side:
Using SST and a press, install a new bearing (inner race) to the counter gear.
SST : 09316-60011
09316-00011
09613-22011
SST : 09950-60010
09951-00420
HINT
Disassemble SST (09613-22011) and only use the tube part.
(b) for Rear Transfer Case Side:
Using SST and a press, install a new bearing (inner race) to the counter gear.
SST : 09316-60011
09316-00011
SST : 09950-60010
09951-00420
9. ADJUST COUNTER GEAR BEARING PRELOAD
(a) Using a vernier caliper and precision straightedge, measure dimension A between the top surface of the front transfer case [*1] and the top surface of the counter gear bearing (outer race) [*2].
Text in Illustration
HINT
Perform the measurement at 3 locations at intervals of 120° around the circumference of the outer race and calculate the average.
NOTICE:
Perform the measurements with the idler gear assembly removed.
(b) Using a vernier caliper and precision straightedge, measure dimension B between the top surface of the rear transfer case [*1] and the surface which contacts the transfer counter gear shim [*2].
Text in Illustration
NOTICE:
Do not add the thickness of the precision straightedge.
(c) Using the formula below, calculate the thickness of the transfer counter gear shim and select an appropriate shim from the table.
Transfer counter gear shim thickness:
Dimension B - Dimension A
Transfer Counter Gear Shim Thickness:
(d) Using SST and a press, install the shim and a new bearing (outer race) to the rear transfer case.
SST : 09950-60020
09951-00750
SST : 09950-70010
09951-07100
(e) Install the counter gear to the front transfer case.
(f) Install the rear transfer case with the 7 bolts to the front transfer case.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
(g) Install the companion flange to the transfer assembly, and then using SST, hold the companion flange in place.
SST : 09213-58014
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.
(h) Tighten the companion flange bolt.
Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)
Text in Illustration
(i) Remove SST and turn the counter gear back and forth to settle the bearing.
(j) Using a torque wrench, measure the turning torque of the counter gear bearing (counter gear preload).
Standard turning torque:
0.66 to 1.18 N*m (6.7 to 12.0 kgf*cm, 5.8 to 10.4 in.*lbf)
NOTICE:
Perform the measurements with the idler gear assembly removed.
HINT
Measure the turning torque while turning the counter gear at 60 rpm (1 rotation per second).
* If the turning torque is not as specified, replace the counter gear shim with one of a different thickness so that the measured value is within the standard range.
(k) Using SST, hold the companion flange in place.
SST : 09213-58014
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.
(l) Remove the companion flange bolt and companion flange from the transfer assembly.
Text in Illustration
(m) Remove the 7 bolts from the rear transfer case.
(n) Remove the counter gear.
10. INSTALL TRANSFER OIL PUMP PLATE SUB-ASSEMBLY
(a) Install the drive rotor and driven rotor to the front transfer case.
(b) Install the plate pin to the oil pump plate.
(c) Install the plate to the front transfer case.
11. INSTALL TRANSFER IDLER GEAR BEARING (for Front Transfer Case Side)
(a) Using SST and a press, install a new bearing (outer race) to the front transfer case.
SST : 09950-60020
09951-00890
SST : 09950-70010
09951-07100
12. INSTALL TRANSFER IDLER GEAR BEARING
(a) for Front Transfer Case Side:
Using SST and a press, install a new bearing (inner race) to the idler gear.
SST : 09554-22010
(b) for Rear Transfer Case Side:
Using SST and a press, install a new bearing (inner race) to the idler gear.
SST : 09950-60010
09951-00540
SST : 09554-22010
13. ADJUST TRANSFER IDLER GEAR BEARING PRELOAD
(a) Install the counter gear to the front transfer case.
(b) Install the idler gear to the front transfer case.
(c) Using a vernier caliper and precision straightedge, measure dimension A between the top surface of the front transfer case [*1] and the top surface of the idler gear bearing (outer race) [*2].
Text in Illustration
HINT
Perform the measurement at 3 locations at intervals of 120° around the circumference of the outer race and calculate the average.
(d) Using a vernier caliper and precision straightedge, measure dimension B between the top surface of the rear transfer case [*1] and the surface which contacts the transfer idler gear shim [*2].
Text in Illustration
NOTICE:
Do not add the thickness of the precision straightedge.
(e) Using the formula below, calculate the thickness of the transfer idler gear shim and select an appropriate shim from the table.
Transfer idler gear shim thickness:
Dimension B - Dimension A
Transfer Idler Gear Shim Thickness:
(f) Using SST and a press, install the shim and a new bearing (outer race) to the rear transfer case.
SST : 09950-60020
09951-00780
09951-00890
09952-06010
SST : 09950-70010
09951-07100
(g) Install the rear transfer case with the 7 bolts to the front transfer case.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
(h) Install the companion flange to the transfer assembly, and then using SST, hold the companion flange in place.
SST : 09213-58014
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.
(i) Tighten the companion flange bolt.
Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)
Text in Illustration
(j) Remove SST and turn the idler gear back and forth to settle the bearing.
(k) Using a torque wrench, measure the turning torque of the idler gear bearing (idler gear preload).
Standard turning torque:
1.54 to 2.64 N*m (15.7 to 26.9 kgf*cm, 13.6 to 23.4 in.*lbf)
NOTICE:
The measured turning torque for the idler gear preload is the combined preload of the idler gear and counter gear.
HINT
Measure the turning torque while turning the counter gear at 60 rpm (1 rotation per second).
* If the turning torque is not as specified, replace the idler gear shim with one of a different thickness so that the measured value is within the standard range.
(l) Using SST, hold the companion flange in place.
SST : 09213-58014
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.
(m) Remove the companion flange bolt and companion flange from the transfer assembly.
Text in Illustration
(n) Remove the 7 bolts and rear transfer case from the front transfer case.
(o) Remove the idler gear and counter gear from the front transfer case.
14. INSTALL TRANSFER OIL COOLER RELIEF VALVE
(a) Install the relief valve to the front transfer case.
(b) Install the compression spring and valve plate to the front transfer case with the bolt.
Torque : 6.7 Nm (68 kgf-cm, 59 in-lbf)
NOTICE:
Be careful to prevent the relief valve compression spring from jumping out.
15. INSTALL NO. 1 TRANSFER OIL STRAINER
(a) Install the oil strainer to the front transfer case.
16. INSTALL TRANSFER OIL SEPARATOR
(a) Install the oil separator with the 3 bolts.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)
17. INSTALL DRIVE PINION COMPANION FLANGE OIL SEAL
(a) Using SST and a hammer, install a new oil seal to the companion flange.
SST : 09950-60010
09951-00420
SST : 09950-70010
09951-07100
Standard oil seal depth:
0 to 0.3 mm (0 to 0.0118 in.)
NOTICE:
* Do not tap in the oil seal at an angle.
* Do not tap in the oil seal excessively.
(b) Coat the lip of the outer shaft lever oil seal with MP grease.
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].
Text in Illustration
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].
Text in Illustration
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 : 09213-58014
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)
Text in Illustration
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)