Reassembly
MF1A TRANSFER / 4WD / AWD: TRANSFER ASSEMBLY: REASSEMBLY
1. INSTALL TRANSFER DRIVEN PINION REAR BEARING
(a) Using SST and a press, press the transfer driven pinion rear bearing (outer race).
Text in Illustration
SST : 09950-60010
09951-00620
SST : 09950-70010
09951-07150
NOTICE:
Keep the transfer case horizontal using wooden blocks, etc.
(b) Apply gear oil to the driven pinion rear bearing (outer race).
2. INSTALL TRANSFER OUTPUT SHAFT WASHER
(a) Install the transfer output shaft washer onto the transfer case.
HINT
Install the same washer as the one removed.
(b) Apply gear oil to the transfer output shaft washer.
3. INSTALL TRANSFER DRIVEN PINION FRONT BEARING
(a) Apply gear oil to the inner surface of the transfer case.
(b) Using SST, install the transfer driven pinion front bearing (outer race).
Text in Illustration
SST : 09950-60010
09951-00610
09951-00620
09951-00650
SST : 09950-60020
09951-00680
(c) Using SST and a press, press the transfer driven pinion front bearing (inner race).
Text in Illustration
SST : 09506-30012
4. INSTALL TRANSFER DRIVEN PINION
(a) Install the transfer driven pinion.
(b) Install a new transfer pinion bearing spacer and transfer driven pinion rear bearing (inner race).
NOTICE:
Install the transfer pinion bearing spacer with the larger inner diameter facing forward as shown in the illustration.
(c) Install a new transfer gear nut.
5. ADJUST DRIVEN PINION PRELOAD
(a) Using SST and a torque wrench, secure the transfer driven pinion, and tighten the transfer gear nut 5° to 10°.
SST : 09326-20011
SST : 09556-16030
(b) Using SST and a torque wrench, measure the driven piston preload.
SST : 09326-20011
Driven Pinion Preload (at Starting):
without SST - Torque : 270 to 420 Nm (2754 to 4282 kgf-cm, 200 to 309 ft-lbf)
with SST - Torque : 255 to 396 Nm (2601 to 4038 kgf-cm, 188 to 291 ft-lbf)
NOTICE:
* If the preload is more than the specification, replace the transfer pinion bearing spacer with a new one. Do not loosen the transfer gear nut to reduce the preload.
* If the preload is not sufficient, adjust the transfer 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 transfer gear nut exceeds the specified torque, if the preload is insufficient, loosen the transfer 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 transfer driven pinion. Then perform the procedure again. If the tightening torque is less than the specified torque, replace the transfer pinion bearing spacer with a new one and adjust it.
HINT
* The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).
* The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.) Service Precautions.
* The "with SST" torque value is effective when SST is parallel to the torque wrench.
6. INSTALL TRANSFER RING GEAR
(a) Clean the contact surface of the transfer ring gear and transfer ring gear mounting case.
(b) Clean and degrease the 12 bolt holes of the transfer ring gear.
(c) Heat the transfer ring gear in boiling water.
(d) Carefully remove the transfer ring gear from the boiling water.
CAUTION:
Use thick gloves to protect hands as the ring gear is hot.
(e) After the moisture on the transfer ring gear has completely evaporated, quickly align the matchmarks, set the ring gear onto the transfer ring gear mounting case.
Text in Illustration
(f) Clean and degrease the 12 bolts.
(g) Apply adhesive to 2 or 3 threads on the ends of the 12 bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(h) Install the 12 bolts.
Torque : 99 Nm (1005 kgf-cm, 73 ft-lbf)
HINT
* Tighten the bolts evenly in a diagonal pattern using several steps.
* Tighten the bolts after the transfer ring gear has cooled down sufficiently.
7. INSTALL RING GEAR MOUNTING CASE BEARING
(a) Install the ring gear mounting case bearing (RH side).
(1) Using SST and a press, press the ring gear mounting case bearing (inner race).
Text in Illustration
SST : 09950-60010
09951-00420
(2) Install the ring gear mounting case bearing (outer race).
(3) Apply gear oil to the ring gear mounting case bearing.
(b) Install the ring gear mounting case bearing (LH side).
(1) Using SST and a press, press the ring gear mounting case bearing (inner race).
Text in Illustration
SST : 09223-00010
SST : 09726-40010
(2) Install the ring gear mounting case plate washer onto the transfer case.
HINT
Use a new washer with the same thickness as the one removed when installing the bearing.
(3) Using SST and a press, press the ring gear mounting case bearing (outer race).
Text in Illustration
SST : 09950-60010
09951-00620
SST : 09950-70010
09951-07200
(4) Apply gear oil to the ring gear mounting case bearing.
8. INSTALL TRANSFER RING GEAR MOUNTING CASE
(a) Apply gear oil to the transfer ring gear mounting case.
(b) Install the transfer ring gear mounting case.
9. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER
(a) 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
10. INSTALL NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER
(a) Using a brass bar and a hammer, install the No. 2 transfer ring gear mounting case washer.
HINT
Use the No. 2 washer with the same thickness as the one removed.
11. INSTALL TRANSFER BEARING CAP
(a) Install the transfer bearing cap with the 2 bolts.
Torque : 63 Nm (644 kgf-cm, 47 ft-lbf)
12. INSPECT RING GEAR BACKLASH
(a) Set a dial indicator perpendicular to a transfer ring gear tooth tip. Secure the transfer driven pinion in place and move the transfer ring gear back and forth to measure the backlash.
Backlash:
0.14 to 0.25 mm (0.00552 to 0.00984 in.)
NOTICE:
Check at least 3 positions on the circumference of the transfer ring gear.
(b) If the backlash is outside the specified range, select a ring gear mounting case plate washer from the table below and install it to meet the specified range.
Text in Illustration
Washer Thickness
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION
(a) Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.
(b) Rotate the ring gear 10 times or more.
(c) Rotate the ring gear to inspect the tooth contact pattern.
Text in Illustration
(d) 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
NOTICE:
When the transfer output shaft washer thickness is changed, readjust the backlash Disassembly.
Washer Thickness
14. INSPECT AND ADJUST TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the total preload.
SST : 09326-20011
Total Preload (at Starting):
HINT
* Turn the transfer driven pinion counterclockwise and clockwise several times.
* The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).
* The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.) Service Precautions.
* The "with SST" torque value is effective when SST is parallel to the torque wrench.
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
Washer Thickness
(b) Using a chisel and a hammer, stake the transfer gear nut.
15. INSTALL TRANSFER CASE RH OIL SEAL
(a) Apply a small amount of MP grease to the lip of a new transfer case RH oil seal.
(b) Using SST and a hammer, drive in the oil seal into the transfer case until it reaches the position as shown in the illustration.
Text in Illustration
SST : 09950-60010
09951-00350
09951-00580
09952-06010
SST : 09950-70010
09951-07150
Drive in depth:
33.5 to 34.5 mm (1.32 to 1.35 in.)
NOTICE:
Make sure that the oil seal is not tilted.
16. INSTALL TRANSFER CASE OIL SEAL
(a) Apply a small amount of MP grease to the lip of a new transfer case oil seal.
(b) Using SST and a hammer, drive in the oil seal into the transfer case until it reaches the position as shown in the illustration.
Text in Illustration
SST : 09608-10010
SST : 09950-70010
09951-07150
Drive in depth:
9.5 to 10.5 mm (0.375 to 0.413 in.)
17. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
(a) Apply a small amount of MP grease to the lip of a new transfer extension housing type T oil seal.
(b) Using SST and a hammer, drive in the oil seal into the transfer extension housing until it reaches the position as shown in the illustration.
Text in Illustration
SST : 09325-20010
Drive in depth:
1.1 to 1.9 mm (0.0434 to 0.0748 in.)
18. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR
(a) Using SST and a press, press in a new transfer 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
(a) Remove any FIPG material and be careful not to drop oil on the contact surfaces of the transfer extension housing and the transfer case.
(b) Degrease the surfaces with a non-residue solvent.
(c) Apply FIPG to the transfer extension housing.
Text in Illustration
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
(d) Install the transfer extension housing with the 4 bolts onto the transfer case.
Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)
NOTICE:
Assemble the transfer extension housing within 10 minutes after the FIPG application.
20. SEPARATE TRANSFER ASSEMBLY
(a) Remove the transfer assembly from the overhaul attachment.
21. INSTALL TRANSFER CASE STRAIGHT PIN
(a) Using a plastic hammer, drive in the 4 new transfer case straight pins into the transfer case positions shown in the illustration.
Text in Illustration
22. INSTALL TRANSFER CASE BREATHER PLUG
(a) Using SST and a hammer, tap in a new transfer case breather plug.
SST : 09612-10093
09612-10061
23. INSTALL BREATHER OIL DEFLECTOR
(a) Install the breather oil deflector with the bolt.
Torque : 6.5 Nm (66 kgf-cm, 58 in-lbf)
24. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY
(a) Remove any FIPG material and be careful not to drop oil on the contact surfaces of the transfer case cover and the transfer case.
(b) Degrease the surfaces with a non-residue solvent.
(c) Apply FIPG to the transfer case cover.
Text in Illustration
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
(d) Clean and degrease the 2 bolts (A) and the installation hole in the transfer case.
(e) Apply adhesive to 2 or 3 threads on the ends of the bolt (A).
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(f) Install the transfer case cover with the 8 bolts.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
NOTICE:
* Wait for at least 1 hour after installing the transfer case cover before adding transfer oil.
* Assemble the transfer case cover within 10 minutes after the FIPG application.
25. INSTALL TRANSFER DRAIN PLUG
(a) Install a new gasket and the transfer drain plug.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
26. INSTALL NO. 1 TRANSFER CASE PLUG
(a) Install a new gasket and the No. 1 transfer case plug.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
27. INSTALL NO. 2 TRANSFER CASE PLUG
(a) Install a new gasket and the No. 2 transfer case plug.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
28. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT
(a) Install the 4 new transfer and transaxle setting stud bolts onto the transfer case positions shown in the illustration.
Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)
Text in Illustration
