TRANSFER CASE REAR OIL SEAL REPLACEMENT


  1. DRAIN TRANSFER OIL


    1. A01H0MSE02
      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 PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  3. REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01H0Y8E01

      Using SST and a hammer, loosen the staked part of the transfer output shaft nut.

      SST
      09930-00010

      Note


      • Completely loosen the staked part of the transfer output shaft nut.

      • Do not damage the threads of the No. 1 differential case.

      • Use SST with the tapered surface facing the No. 1 differential case.

      • Do not grind the end of SST with a grinder or other tool.

    2. A01GWM6E01

      Using SST, hold the companion flange in place.

      SST
      09330-00021
      09950-30012   ( 09955-03040 )

    3. Using a 30 mm socket wrench, remove the transfer output shaft nut.

    4. A01H0JPE01

      Using SST, remove the companion flange and 2 transfer output shaft washers.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040 )

  4. REMOVE TRANSFER EXTENSION HOUSING OIL SEAL


    1. A01H168E01

      Using SST, remove the oil seal.

      SST
      09308-00010

      Note

      Be careful not to damage the surface of the transfer extension housing that contacts the oil seal.

  5. INSTALL TRANSFER EXTENSION HOUSING OIL SEAL


    1. A01GXCKE01

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

      SST
      09316-60011   ( 09316-00011 )
      Standard oil seal depth
      12.0 to 12.5 mm (0.4724 to 0.4921 in.) from the top edge of the case

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

  6. INSTALL DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. Temporarily install the 2 transfer output shaft washers and companion flange to the transfer assembly with a new transfer output shaft nut.

    2. A01GWCXE01

      Using SST, hold the companion flange in place.

      SST
      09330-00021
      09950-30012   ( 09955-03040 )

    3. Using a 30 mm socket wrench, tighten the transfer output shaft nut.

      Torque:
      142 N*m  { 1448 kgf*cm, 105 ft.*lbf }

    4. Using a chisel and hammer, stake the transfer output shaft nut.

  7. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  8. 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. A01H1Z1E02
      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.