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 hybrid vehicle transmission.

      Note

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

    2. A01H0F4

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

    3. Slowly tilt the hybrid vehicle transmission 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 hybrid vehicle transmission, align the knock pins with the knock pin holes and install the transfer.

      A01GZUV

      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.

      A01GZ8Y
      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }
    6. A01H100

      Connect the rear engine mounting member with the 4 bolts.

      Torque:
      35 N*m  { 354 kgf*cm, 26 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. A01GWJ9

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

    9. A01H0MN

      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. A01GY5OE02

      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. A01H22WE02

      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. A01H0PLE01

      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. A01GX04E01

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

      Torque:
      25 N*m  { 255 kgf*cm }
    18. A01GWJ9

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

      Torque:
      for bolt
      35 N*m  { 354 kgf*cm, 26 ft.*lbf }
      for nut
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
    19. A01GZTF

      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

    Click here

  3. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  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. 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.

  5. INSTALL SERVICE PLUG GRIP

    Click here

  6. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  7. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY


    1. A01GYMY

      Temporarily connect the shifting rod to the connecting rod swivel with the nut.

      Tech Tips

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

    2. Attach the 2 claws to install the shift lock release button cover.

  8. INSPECT FOR OIL LEAK

  9. INSPECT FOR EXHAUST GAS LEAK


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

  10. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. A01H26PE01

      Install the front lower suspension member protector 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 }

  11. INSTALL NO. 1 ENGINE UNDER COVER


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

  12. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


    1. Install the front wheel opening extension pad LH with the 5 screws.

  13. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

    Tech Tips

    Use the same procedure described for the LH side.

  14. INSTALL NO. 2 ENGINE UNDER COVER


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

  15. INSTALL FRONT CENTER FLOOR COVER (w/ 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 }

  16. INSTALL INVERTER COVER ASSEMBLY LH (for RHD)


    1. A01GWCS

      Align the locating hole of the inverter cover assembly LH with the locating pin of the inverter with converter assembly. Set the inverter cover assembly LH to the inverter with converter assembly.

    2. Press the positions where the clips are to secure the inverter cover assembly LH to the inverter with converter assembly.

  17. INSTALL INVERTER COVER ASSEMBLY RH (for LHD)


    1. A01GW7A

      Align the locating hole of the inverter cover assembly RH with the locating pin of the inverter with converter assembly. Set the inverter cover assembly RH to the inverter with converter assembly.

    2. Press the positions where the clips are to secure the inverter cover assembly RH to the inverter with converter assembly.

  18. INSTALL MOTOR CABLE COVER LH (for RHD)


    1. A01H1LZ

      Install the motor cable cover LH with the 2 clips.

  19. INSTALL MOTOR CABLE COVER RH (for LHD)


    1. A01H000

      Install the motor cable cover RH with the 2 clips.

  20. INSTALL COWL TOP VENTILATOR LOUVER RH (for LHD)


    1. A01H0KV

      Install the cowl top ventilator louver RH with the 6 clips.

      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.

  21. INSTALL COWL TOP VENTILATOR LOUVER LH (for RHD)

    Tech Tips

    Use the same procedures described for LHD vehicles.

  22. INSTALL ENGINE ROOM SIDE COVER LH


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

  23. INSTALL ENGINE ROOM SIDE COVER RH


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

  24. INSTALL NO. 1 AIR CLEANER INLET


    1. A01GYPCE01

      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 }

  25. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY


    1. A01GWDEE01

      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.

  26. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01GZ6XE01

      After sliding the V-bank cover sub-assembly from the vehicle front to the rear to attach the 2 clips labeled A, attach the 4 clips labeled B and install the V-bank cover sub-assembly.

      CAUTION:


      • Make sure the clips are attached securely.

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

  27. INSTALL BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02
      Text in Illustration
      *A for Standard
      *B for Ottoman

      Attach the battery service hole cover LH with the clip and fastening tape.

  28. INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)


    1. A01GXQQ

      Attach the 2 clips to install the deck trim side board LH.

  29. INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)

    A01GZ3P

  30. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    A01GWKI

  31. INSTALL FRONT WHEEL

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

  32. INSPECT AND ADJUST TRANSMISSION FLUID LEVEL


    1. Click here