TRANSFER CASE FRONT OIL SEAL (for RH Side): Replacement

1. Remove the 4 bolts, 2 compression springs and front exhaust pipe assembly.
2. Remove the 2 gaskets.

1. Remove the transfer drain plug and gasket to drain the transfer oil.
2. Install a new gasket and the transfer drain plug.

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

DP-8 for 2AZ-FE

Fig 1: Locating Bolts, Compression Springs And Front Exhaust Pipe Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the transfer case front oil seal from the transfer case.

   SST 09308-00010 

   NOTE: Do not damage the oil seal contact surface on the case.
   Fig 2: Removing Transfer Case Front Oil Seal From Transfer Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, drive in a new transfer case front oil seal into the transfer case until it reaches the position shown in the illustration.

   SST 09950-60010 (09951 -00350, 09951 -00580, 09952-06010), 09950-70010 (09951-07150) 

   Drive in depth: 

   33.7 to 34.3 mm (1.3268 to 1.3504 in.) 

   NOTE: Do not tilt the oil seal during installation.
   Fig 3: Driving In Transfer Case Front Oil Seal Into Transfer Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a small amount of MP grease to the lip of the oil seal.

DP-19 for 2AZ-FE

1. Using a vernier caliper, measure the free length of the compression springs.
   COMPRESSION SPRINGS FREE LENGTH REFERENCE CHART
   
   

   Minimum

   41.5 mm (1.63 in.)

   HINT:

   If the free length is less than the minimum, replace the compression spring.

2. Remove the remains on exhaust manifold converter with wire brush.
   Fig 4: Measuring Free Length Of Compression Springs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Fully insert a new gasket to the exhaust manifold.
   NOTE:

   • Be sure to install the gasket in the correct direction.
   • Do not reuse the gasket.
   • Do not damage the gasket.
     Fig 5: Identifying Exhaust Manifold Gasket

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the front exhaust pipe assembly with the 4 bolts and 2 compression springs.

   Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf)