Transfer Assembly: Inspection

WARNING: This page is about a different car, the 2007 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT CENTER DIFFERENTIAL CARRIER ASSEMBLY
1. Using a feeler gauge, measure the center differential carrier pinion gear thrust clearance.
  Standard clearance: 0.2 to 0.5 mm (0.008 to 0.020 In.)
  
  If the clearance is greater than the standard clearance, replace the center differential carrier.
  
  Fig 1: Measuring Center Differential Carrier Pinion Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CENTER DIFFERENTIAL CLUTCH DISC SET
1. Check whether the sliding surfaces of the disc and flange are worn or burnt. If necessary, replace them.
  NOTE:
  - If the lining of the disc Is peeled off or discolored, or If any part of the printed numbers Is damaged, replace all discs.
  - Before assembling new discs, soak them In ATF for at least 15 minutes.
    
    Fig 2: Identifying 2nd Brake Disc Set
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY
1. Using vernier calipers, measure the free length of the spring together with the spring seat.
  Standard free length: 15.2 to 15.8 mm (0.5984 to 0.6220 in.)
  
  If the free length is shorter than the standard free length, replace the transfer direct clutch return spring.
  
  Fig 3: Measuring Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER DIRECT CLUTCH DRUM
1. Using a cylinder gauge, measure the inside diameter of the transfer direct clutch drum.
  Standard inside diameter: 65.00 to 65.06 mm (2.559 to 2.564 in.)
  
  If the inside diameter is greater than the standard inside diameter, replace the transfer direct clutch drum.
  
  Fig 4: Identifying Transfer Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSFER CENTER SUPPORT
1. Using a cylinder gauge, measure the inside diameter of the transfer center support.
  Standard inside diameter: 49.9 to 50.1 mm (1.965 to 1.972 in.)
  
  If the inside diameter is greater than the standard inside diameter, replace the transfer center support.
  
  Fig 5: Identifying Transfer Center Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002