Reassembly
GF1A TRANSFER: TRANSFER ASSEMBLY: REASSEMBLY
1. INSTALL BREATHER OIL DEFLECTOR
(a) Install the deflector with the 2 bolts.
Torque : 6.5 Nm (66 kgf-cm, 58 in-lbf)
2. INSTALL RING GEAR MOUNTING CASE PLATE WASHER
(a) Install a new washer to the transfer case.
HINT
Install a washer of the same thickness as before.
3. INSTALL TRANSFER RING GEAR MOUNTING CASE NO. 2 WASHER
(a) Install a new washer to the cover.
HINT
Install a washer of the same thickness as before.
4. INSTALL TRANSFER RING GEAR MOUNTING CASE
(a) Using SST and a press, press in the mounting case to the ring gear.
SST : 09316-12010
SST : 09950-60010
09951-00560
5. INSTALL SHAFT SNAP RING
(a) Using a snap ring expander, install a new snap ring.
6. INSTALL RING GEAR MOUNTING CASE BEARING (for RH side)
(a) Using SST and a press, press in the bearing (race) to the cover.
SST : 09950-60020
09951-00750
09952-06010
SST : 09950-70010
09951-07150
(b) Using SST and a press, press in the bearing to the mounting case.
SST : 09336-16010
SST : 09950-60010
09951-00400
(c) Apply gear oil to the bearing.
7. INSTALL RING GEAR MOUNTING CASE BEARING (for LH side)
(a) Using SST and a press, press in the bearing (race) to the case.
SST : 09950-60010
09951-00540
09951-00620
09952-06010
SST : 09950-70010
09951-07150
(b) Using SST and a press, press in the bearing to the mounting case.
SST : 09336-16010
SST : 09950-60010
09951-00560
(c) Apply gear oil to the mounting case bearing.
8. INSTALL TRANSFER OUTPUT SHAFT WASHER
(a) Install the washer to the driven pinion.
9. INSTALL TRANSFER DRIVEN PINION FRONT BEARING
(a) Using SST and a press, press in the bearing to the driven pinion.
SST : 09950-60010
09951-00440
SST : 09950-60020
09951-00750
SST : 09950-70010
09951-07150
10. INSTALL TRANSFER OUTPUT REAR SHAFT DUST DEFLECTOR
(a) Using SST and a press, press in the dust deflector to the output shaft.
SST : 09316-12010
11. INSTALL TRANSFER OUTPUT REAR SHAFT SUB-ASSEMBLY
(a) Using SST and a press, press in the output rear shaft to the driven pinion.
SST : 09316-12010
(b) Install a new nut to the output shaft.
Torque : 360 Nm (3671 kgf-cm, 266 ft-lbf)
12. INSTALL TRANSFER SHAFT
(a) Install a new O-ring to the driven pinion.
(b) Install the driven pinion to the case with the 5 bolts.
Torque : 38 Nm (390 kgf-cm, 28 ft-lbf)
13. INSPECT DRIVEN PINION PRELOAD
(a) Using a torque wrench, measure the preload.
Standard preload (turning):
0.17 to 1.86 N*m (1.7 to 19.0 kgf*cm, 1.5 to 16.5 in.*lbf)
14. INSTALL TRANSFER RING GEAR
(a) Coat 3 or 4 teeth at the 4 different positions on the ring gear with Prussian blue.
(b) Install the mounting case to the transfer case.
15. INSTALL NO. 1 TRANSFER CASE COVER
(a) Install the transfer cover with the 8 bolts.
Torque : 47 Nm (480 kgf-cm, 35 ft-lbf)
16. ADJUST RING GEAR BACKLASH
(a) Using a dial indicator, measure the backlash of the ring gear at 3 positions at least.
Standard backlash:
0.10 to 0.20 mm (0.0039 to 0.0079 in.)
HINT
The measure values should be used as reference when selecting washer, so take a note of the values. If the backlash is not within the specification, replace the washer on the ring gear side with one of a different thickness using the following procedure.
Standard washer thickness:
17. ADJUST TOTAL PRELOAD
(a) Using a torque wrench, measure the total preload.
Driven pinion preload:
0.28 to 0.79 N*m (2.86 to 8.06 kgf*cm, 2.48 to 7.0 in.*lbf)
HINT
Turn the driven pinion counterclockwise and clockwise several times.
If the preload is not as specified, select a proper washer again.
Standard washer thickness:
18. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Rotate the ring gear several times.
(b) Peer into the service filler hole or remove the ring gear to check the tooth contact pattern.
NOTICE:
* Check the tooth contact pattern at 4 or more positions around the circumference of the ring gear.
* When replacing washers (backlash adjustment, preload adjustment or tooth contact adjustment), reapply Prussian blue.
HINT
The Prussian blue pattern indicates the tooth contact points.
(c) If the teeth are not contacting properly, select a driven pinion bearing front (outer race) side washer from the chart and install the washer.
NOTICE:
If a washer (for tooth contact adjustment) is replaced with one of a different thickness, the backlash will also change. Therefore, it is necessary to adjust the backlash.
(d) Perform the following procedures for face or flank contact.
(1) Use the backlash adjustment washer (ring gear mounting case washer) to move and adjust the ring gear. (*1)
(2) Perform the ring gear and driven pinion tooth contact inspection again.
HINT
If the tooth contact is incorrect, repeat step *1.
(3) Perform the ring gear and driven pinion backlash inspection. If the ring gear and driven pinion backlash is not within the standard range, replace the ring gear and driven pinion with new ones.
(e) Perform the following procedures for heel or toe contact.
(1) Select a transfer driven pinion bearing front (outer race) side washer (transfer output shaft washer) from the chart and install the washer.
NOTICE:
Do not reuse a transfer pinion bearing spacer.
Standard washer thickness:
19. COMPLETELY INSTALL TRANSFER SHAFT
(a) Using a screwdriver and hammer, unstake the pinion gear nut.
(b) Install the 5 bolts with the transfer shaft to the case.
Torque : 38 Nm (390 kgf-cm, 28 ft-lbf)
(c) Install the No. 1 transfer case cover.
(1) Using non-residue solvent, clean the contact surfaces of the housing and cover.
(2) Apply seal packing to the cover as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
(3) Install the 8 bolts with the cover to the case.
Torque : 47 Nm (480 kgf-cm, 35 ft-lbf)
20. INSTALL TRANSFER CASE OIL SEAL LH Replacement
21. INSTALL TRANSFER CASE OIL SEAL RH Replacement
22. INSTALL TRANSFER CASE STRAIGHT PIN
(a) Using a plastic-faced hammer, install the straight pin as shown in the straight pin.
23. INSTALL TRANSFER CASE BREATHER PLUG
(a) Using SST and a hammer, tap in a new breather plug.
SST : 09612-10093
09612-10061
24. INSTALL TRANSFER DRAIN PLUG
(a) Install a new gasket and the plug to the transfer case.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
25. INSTALL TRANSFER CASE NO. 1 PLUG
(a) Install a new gasket and the plug to the transfer case.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
26. INSTALL TRANSFER CASE NO. 2 PLUG
(a) Install a new gasket and the plug to the transfer case.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
27. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT
(a) Apply sealer to stud bolts.
(b) Install the stud bolts.
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)
HINT
Install the transfer side of the stud bolt (see illustration below) to the case.
