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TRANSFER CASE FRONT OIL SEAL REPLACEMENT

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  1. Click here

    DRAIN TRANSFER OIL


    1. A0156Y8

      except 1GR-FE:

      Remove the 2 bolts and transfer dynamic damper.

    2. A01593H

      Remove the 4 bolts and transfer heat insulator.

    3. A015DHZ

      Remove the 7 bolts and lower transfer case protector.

    4. A015BBP

      Remove the filler plug and gasket.

    5. A015AJZ

      Remove the drain plug and gasket, and drain the transfer oil.

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    REMOVE FRONT PROPELLER SHAFT ASSEMBLY

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  3. Click here

    REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. A015731E01

      Using SST and a hammer, release the staked part of the nut.

      09930-00010 09931-00010 09931-00020
      Note:

      • Be sure to use SST with the tapered surface facing the shaft.

      • Do not grind the tip of SST with a grinder, etc.

      • Completely loosen the staked part of the nut when removing it.

      • Do not damage the threads of the transfer driven sprocket.

    2. A015D0JE01

      Using SST to hold the companion flange, remove the lock nut.

      09330-00021
    3. A015E4XE01

      Using SST, remove the companion flange.

      09950-40011 09951-04020 09952-04010 09953-04030 09954-04010 09955-04051 09957-04010 09958-04011

    4. Remove the O-ring from the companion flange.

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    REMOVE FRONT TRANSFER CASE OIL SEAL


    1. A0155D0E01

      Using SST, remove the front transfer case oil seal.

      09308-10010
      09950-40011 09957-04010
      Note:

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

      • Apply grease to the tip of SST center bolt before use.

  5. Click here

    INSTALL FRONT TRANSFER CASE OIL SEAL


    1. Apply transfer oil to the spline of the driven sprocket.

    2. A015C8EE01

      Using SST and a hammer, tap in a new front transfer case oil seal.

      09613-26010
      Note:

      The front transfer case oil seal should be installed completely.

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    INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Install the companion flange onto the drive sprocket.

    2. A015D0JE01

      Using SST to hold the companion flange, install a new O-ring and a new companion flange lock nut.

      09330-00021
      127 N*m 1299 kgf*cm 94 ft.*lbf
    3. A01573YE01

      Using a chisel and hammer, stake the companion flange lock nut.

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    INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    (Click here)

  8. Click here

    ADD TRANSFER OIL


    1. A015AJZ

      Install a new gasket onto the drain plug and then install the plug.

      37 N*m 377 kgf*cm 27 ft.*lbf
    2. A0159ZOE08

      Add oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler plug hole.

      Note:

      • Add oil slowly.

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

    3. Wait approximately 5 minutes and check that the oil level has not changed.

    4. A015BBP

      Install a new gasket onto the filler plug and then install the plug.

      37 N*m 377 kgf*cm 27 ft.*lbf
    5. A015DHZ

      Install the lower transfer case protector with the 7 bolts.

      14 N*m 139 kgf*cm 10 ft.*lbf
    6. A01593H

      Install the transfer heat insulator with the 4 bolts.

      30 N*m 306 kgf*cm 22 ft.*lbf
    7. A0156Y8

      except 1GR-FE:

      Install the transfer dynamic damper with the 2 bolts.

      12 N*m 122 kgf*cm 9 ft.*lbf
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    CHECK FOR TRANSFER OIL LEAK