TRANSFER ASSEMBLY INSTALLATION


  1. INSTALL TRANSFER ASSEMBLY


    1. Set an engine lift and wooden blocks or equivalent against the rear engine mounting member and support the automatic transmission assembly.

      Note

      Do not set the wooden blocks or equivalent against the oil pan of the transmission.

    2. Remove the 4 bolts and disconnect the rear engine mounting member.

    3. Slowly tilt the automatic transmission assembly away from the vehicle.

      Note

      Be careful of the exhaust manifold and wire harnesses when tilting the transmission.

    4. Using a jack and wooden blocks or equivalent, raise the transfer assembly so that it is level with the automatic transmission assembly, align the knock pins with the knock pin holes and install the transfer.

      A01GIFS

      Note


      • Be careful not to damage the oil seal.

      • Be careful not to drop the transfer assembly.

      • Be sure to perform this procedure with several people as the transfer assembly is very heavy.

    5. Install the 10 bolts.

      A01GHQ4
      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

    6. Connect the rear engine mounting member with the 4 bolts.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

    7. Support the transfer assembly with a jack and wooden blocks or equivalent.

      Note

      Do not set the wooden blocks or equivalent against the oil pan of the transmission.

    8. Remove the 4 bolts, 5 nuts, No. 3 rear engine mounting insulator and rear engine mounting member.

    9. A01GMUS

      Install the bolt.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

    10. Completely remove any oil or the like and clean the constant velocity universal joint washers and the contact surfaces of the front propeller shaft assembly, transfer and front differential.

    11. Install the front propeller shaft assembly to each companion flange.

    12. A01GLM2E03
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the transfer companion flange and front propeller shaft assembly, and then temporarily install the front propeller shaft assembly and 2 universal joint washers to the transfer companion flange with 6 new bolts.

    13. A01GI16E01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the front differential companion flange and front propeller shaft assembly, and then temporarily install the front propeller shaft assembly and 2 universal joint washers to the front differential companion flange with 6 new bolts.

    14. Using a screwdriver with a round shaft, hold the transfer companion flange to prevent the front propeller shaft assembly from turning.

    15. A01GJJPE02
      Text in Illustration
      *a Turn
      *b Hold

      Using a 6 mm hexagon socket wrench, tighten the 6 bolts on the transfer side.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    16. Using a screwdriver with a round shaft, hold the differential companion flange to prevent the front propeller shaft assembly from turning.

    17. A01GIOOE01
      Text in Illustration
      *a Turn
      *b Hold

      Using a 6 mm hexagon socket wrench, tighten the 6 bolts on the front differential side.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    18. Install the rear engine mounting member and No. 3 rear engine mounting insulator with the 4 bolts and 5 nuts.

      Torque:
      for bolt
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }
      for nut
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

    19. Connect the ground cable with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  2. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  3. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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  4. 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.

  5. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY


    1. Temporarily connect the floor shift gear shifting rod sub-assembly to the connecting rod swivel with the nut.

      Tech Tips

      The nut will be tightened to a torque specification during the shift lever position adjustment procedure.

  6. INSPECT FOR OIL LEAK

  7. INSPECT FOR EXHAUST GAS LEAK


    1. If gas is leaking, tighten the areas necessary to stop the leak. Replace the damaged parts as necessary.

  8. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. A01GI4DE01

      Install the front suspension member protector lower with the 9 bolts.

      Torque:
      for bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      except bolt A
      58 N*m  { 593 kgf*cm, 43 ft.*lbf }

  9. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 13 screws and 7 clips.

  10. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 4 screws and 2 clips.

  11. INSTALL FRONT CENTER FLOOR COVER


    1. Install the front center floor cover with the 3 screws, 2 bolts and clip.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  12. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. A01GM4S

      Install the 6 clips and cowl top ventilator louver RH.

      Note

      Be sure to install the cowl top ventilator louver RH properly. If it is not installed properly, water may enter the engine room and cause malfunctions.

  13. INSTALL ENGINE ROOM SIDE COVER LH


    1. Install the engine room side cover LH with the 5 clips.

  14. INSTALL ENGINE ROOM SIDE COVER RH


    1. Install the engine room side cover RH with the 5 clips.

  15. INSTALL NO. 1 AIR CLEANER INLET


    1. A01GIR0E02

      Align the holes with the connection areas labeled A, and attach the No. 1 air cleaner inlet.

    2. Install the No. 1 air cleaner inlet with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  16. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY


    1. A01GLYAE01

      Attach the 4 clips labeled B.

      Note


      • Make sure the clips are attached securely.

      • Attaching the clips forcefully or hitting the top of the clips may damage them.

    2. Install the air cleaner inlet cover sub-assembly with the 5 clips labeled A.

  17. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01GMKRE01

      Slide the cover from the vehicle front toward the rear of the vehicle to attach the 2 clips labeled A, and then attach the 4 clips labeled B to install the V bank cover sub-assembly.

      Note


      • Make sure the clips are attached securely.

      • Attaching the clips forcefully or hitting the top of the clips may damage them.

      • When attaching the clips labeled A, be sure to slide the cover from the front of the vehicle toward the rear of the vehicle.

  18. INSTALL FRONT WHEEL

    Torque:
    140 N*m  { 1428 kgf*cm, 103 ft.*lbf }

  19. INSPECT AND ADJUST TRANSMISSION FLUID LEVEL

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