TRANSFER CASE FRONT OIL SEAL REPLACEMENT


  1. DRAIN TRANSFER OIL


    1. A01GLQSE02
      Text in Illustration
      *1 Filler plug
      *2 Drain plug

      Using a 10 mm hexagon wrench, remove the filler plug and gasket.

    2. Using a 10 mm hexagon wrench, remove the drain plug and gasket, and drain the transfer oil.

  2. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  3. REMOVE TRANSFER CASE PLUG

    A01GNPE

    1. Using a 17 mm straight hexagon wrench, remove the plug and gasket.

  4. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

    A01GI5ZE01

    1. Using SST, hold the companion flange in place and remove the companion flange bolt.

      SST
      09213-58013
      09330-00021

    2. Remove the companion flange from the transfer assembly.

  5. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL

    A01GK55E01

    1. Using SST, tap out the oil seal.

      SST
      09308-00010

      Note

      Be careful not to damage the oil seal or front transfer case contact surface.

  6. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL

    A01GKUAE01

    1. Assemble SST and wrap SST with vinyl tape to hold it together.

      SST
      09316-60011   ( 09316-00011, 09316-00021 )
      09502-24010

    2. Using SST and a hammer, tap in a new oil seal to the position shown in the illustration.

      SST
      09316-60011   ( 09316-00011, 09316-00021 )
      09502-24010
      Standard oil seal depth
      2.5 to 3.0 mm (0.0984 to 0.1181 in.)

    3. Apply a small amount of MP grease to the lip of the oil seal.

  7. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

    A01GKGNE01

    1. Temporarily install the companion flange to the transfer assembly with the companion flange bolt.

    2. Using SST, hold the companion flange in place and tighten the companion flange bolt.

      SST
      09213-58013
      09330-00021
      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

  8. INSTALL TRANSFER CASE PLUG

    A01GNPE

    1. Using a 17 mm straight hexagon wrench, install a new gasket and the plug.

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

  9. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

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  10. ADD TRANSFER OIL


    1. Install a new gasket into the drain plug and then install the drain plug with a 10 mm hexagon wrench.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
    2. A01GNVXE02
      Text in Illustration
      *a 0 to 5 mm (0 to 0.196 in.)

      Add oil so that the oil level is between 0 to 5.0 mm (0 to 0.196 in.) from the bottom lip of the filler plug hole.

      Oil grade
      Toyota Genuine Transfer gear oil LL 80 or equivalent
      Standard capacity
      0.7 liters (0.7 US qts, 0.6 Imp. qts)

      Note


      • Add oil slowly.

      • Add oil a little at a time, waiting several minutes between each addition of oil.

      • Keep the vehicle level during inspection.

    3. Install a new gasket into the filler plug and then install the plug with a 10 mm hexagon wrench.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

    4. Drive the vehicle and check the oil level again.