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Section 170 (Transfer Case): Replacement

WARNING: This page is about a different car, the 2004 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: COMPONENTS: See COMPONENTS 
  1. DRAIN AUTOMATIC TRANSAXLE FLUID 
  2. REMOVE TRANSFER CASE NO. 1 PLUG 
  3. REMOVE TRANSFER DRAIN PLUG 
    1. Remove the drain plug, gasket and drain transfer oil.
  4. REMOVE FRONT WHEEL 
  5. REMOVE FRONT DRIVE SHAFT ASSY RH (See  REMOVAL & INSTALLATION  ) 

    SST 09520-01010, 09520-24010 (09520-32040)

  6. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST, remove the RH bearing retainer oil seal.

      SST 09308-00010

    NOTE: Do not damage the oil-seal-fitted surface of the case.
    Fig 1: Removing Transfer RH Bearing Retainer Oil Seal
    G03062685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST, drive a new oil seal into the case to the position shown.

      SST 09223-4601 1

      NOTE: Do not install the oil seal obliquely.
    2. Apply small amount of MP grease to the oil seal lip.
    Fig 2: Installing Transfer RH Bearing Retainer Oil Seal
    G03062686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DRIVE SHAFT ASSY RH (See  REMOVAL & INSTALLATION  ) 
  9. INSTALL FRONT WHEEL 

    Torque: 103 N.m (1050 kgf.cm, 76 ft.lbf) 

  10. ADD AUTOMATIC TRANSAXLE FLUID 
  11. INSPECT AUTOMATIC TRANSAXLE FLUID (See  ON-VEHICLE INSPECTION  ) 
  12. INSTALL TRANSFER DRAIN PLUG 
    1. Install the drain plug with a new gasket.

      Torque: 49 N.m (500 kgf.cm 36 ft.lbf) 

  13. INSTALL TRANSFER CASE NO. 1 PLUG 
    1. Supply oil up to the level 0 - 5 mm (0 - 0.20 in.) below the lowest end of the plug hole.

      Oil quantity: 0.9 L (0.95 US qts, 0.71 Imp.qts) 

      NOTE: When supplying oil, fill it slowly.
    2. Install the plug No. 1 with a new gasket.

      Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

  14. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See  ADJUSTMENTS & INSPECTION  ) 
  15. CHECK ABS SPEED SENSOR SIGNAL (See  PRE-CHECK  ) 


NOTE: ENGINE COMPONENTS: See COMPONENTS

AUTOMATIC TRANSAXLE COMPONENTS: See COMPONENTS

TRANSFER COMPONENTS: See COMPONENTS 

  1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See  REPLACEMENT  ) 
  2. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (See  REPLACEMENT  ) 
  3. REMOVE TRANSFER ASSY (See  OVERHAUL  ) 
  4. REMOVE CTR DIFFERENTIAL LOCK SLEEVE (See  OVERHAUL  ) 
  5. REMOVE TRANSFER CASE OIL SEAL 
    1. Using SST, remove the oil seal from the case.

      SST 09308-00010

    NOTE: Do not damage the oil-seal-fitted surface of the case.
    Fig 1: Removing Transfer Case Oil Seal
    G03062687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL TRANSFER CASE OIL SEAL 
    1. Using SST, drive a new oil seal into the case to the position shown.

      SST 09387-00010, 09950-70010 (09951-07150)

      NOTE: Do not install it obliquely.
    2. Apply small amount of MP grease to the oil seal lip.
    Fig 2: Installing Transfer Case Oil Seal
    G03062688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL CTR DIFFERENTIAL LOCK SLEEVE (See  OVERHAUL  ) 
  8. INSTALL TRANSFER ASSY (See  OVERHAUL  ) 
  9. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (See  REPLACEMENT  ) 
  10. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See )  REPLACEMENT 
  11. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See )  ADJUSTMENTS & INSPECTION 
  12. CHECK ABS SPEED SENSOR SIGNAL 
    1. ABS WITH EBD & BA & TRAC & VSC SYSTEM (See PRE-CHECK )


NOTE: COMPONENTS: See COMPONENTS 
  1. REMOVE TRANSFER CASE NO. 1 PLUG 
  2. REMOVE TRANSFER DRAIN PLUG 
    1. Remove the drain plug, gasket and drain transfer oil.
  3. REMOVE EXHAUST PIPE ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  4. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (See  OVERHAUL  ) 
  5. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST, remove the oil seal from the extension housing.

      SST 09308-00010

    NOTE: Be careful not to damage the oil-seal-fitted surface and the inside surface of the bush.
    Fig 1: Removing Transfer Extension Housing Type T Oil Seal
    G03062689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST, drive a new oil seal into the extension housing to the position shown.

      SST 09325-20010

      NOTE: Do not install the oil seal obliquely.
    2. Apply small amount of MP grease to the oil seal lip.
    Fig 2: Installing Transfer Extension Housing Type T Oil Seal
    G03062690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. TEMPORARILY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (See  OVERHAUL  ) 
  8. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (See  OVERHAUL  ) 
  9. INSTALL EXHAUST PIPE ASSY (See )  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY 
  10. INSTALL TRANSFER DRAIN PLUG 
    1. Install the drain plug with a new gasket.

      Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

  11. INSTALL TRANSFER CASE NO. 1 PLUG 
    1. Supply oil up to the level 0 - 5 mm (0 - 0.20 in.) below the lowest end of the plug hole.

      Oil quantity: 0.9 L (0.95 US qts, 0.71 Imp.qts) 

      NOTE: When supplying oil, fill it slowly.
    2. Install the No. 1 plug with a new gasket.

      Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

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