CAUTION / NOTICE / HINT
Note
Steps 9 to 16 are temporary reassembly procedures for adjustment purposes.
PROCEDURE
INSTALL BREATHER OIL DEFLECTOR
*A | for K111F |
*B | for U660F, U760F, EA64F, EB61F, EB63F, K114F |
Install a new breather oil deflector to the transfer case with the 2 bolts.
INSTALL TRANSFER RING GEAR MOUNTING CASE
Using SST and a press, press the transfer ring gear mounting case into the transfer ring gear.
Note
Do not put stress on the teeth of the transfer ring gear.
INSTALL SHAFT SNAP RING
Using a snap ring expander, install a new shaft snap ring.
INSTALL RING GEAR MOUNTING CASE BEARING RH
*1 | No. 2 Transfer Ring Gear Mounting Case Washer |
*2 | Ring Gear Mounting Case Bearing RH (Outer Race) |
Install a new No. 2 transfer ring gear mounting case washer to the No. 1 transfer case cover.
Tech Tips
Install a No. 2 transfer ring gear mounting case washer with the same thickness as the one before the disassembly.
Using SST and a press, press the ring gear mounting case bearing RH (outer race) into the No. 1 transfer case cover.
Note
Press in the ring gear mounting case bearing RH (outer race) and No. 2 transfer ring gear mounting case washer until they fit to the edge.
Do not put stress on the rolling contact surface of the ring gear mounting case bearing RH (outer race).
Using SST and a press, press the ring gear mounting case bearing RH (inner race) into the transfer ring gear mounting case.
Note
Do not deform the ring gear mounting case bearing RH (inner race) cage.
Tech Tips
When reusing the ring gear mounting case bearing RH, coat the ring gear mounting case bearing RH with Toyota Genuine Differential gear oil LT API GL-5 or equivalent.
INSTALL RING GEAR MOUNTING CASE BEARING LH
*1 | No. 1 Ring Gear Mounting Case Washer |
*2 | Ring Gear Mounting Case Bearing LH (Outer Race) |
Install a new No. 1 ring gear mounting case washer to the transfer case.
Tech Tips
Install a No. 1 ring gear mounting case washer with the same thickness as the one before the disassembly.
Using SST and a press, press the ring gear mounting case bearing LH (outer race) into the transfer case.
for K111F:
for U660F, U760F, EA64F, EB61F, EB63F, K114F:
Note
Press in the ring gear mounting case bearing LH (outer race) and No. 1 ring gear mounting case washer until they fit to the edge.
Do not put stress on the rolling contact surface of the ring gear mounting case bearing LH (outer race).
Using SST and a press, press the ring gear mounting case bearing LH (inner race) into the transfer ring gear mounting case.
Note
Do not deform the ring gear mounting case bearing LH (inner race) cage.
Tech Tips
When reusing the ring gear mounting case bearing LH, coat the ring gear mounting case bearing LH with Toyota Genuine Differential gear oil LT API GL-5 or equivalent.
INSTALL TRANSFER OUTPUT SHAFT WASHER
Install the transfer output shaft washer to the transfer driven pinion.
INSTALL FRONT TRANSFER DRIVEN PINION BEARING
w/o Washer:
Using SST and a press, press the front transfer driven pinion bearing into the transfer driven pinion.
Note
Do not apply stress to any parts of the front transfer driven pinion bearing inner race or transfer driven pinion other than the flat surfaces.
w/ Washer:
Note
The front transfer driven pinion bearing service kit consists of a front transfer driven pinion bearing and washer.
The supplied washer is used in the transfer driven pinion installation procedure.
Using SST and a press, press the front transfer driven pinion bearing into the transfer driven pinion.
Note
Do not apply stress to any parts of the front transfer driven pinion bearing inner race or transfer driven pinion other than the flat surfaces.
INSTALL REAR TRANSFER OUTPUT SHAFT DUST DEFLECTOR
Using SST and a press, press a new rear transfer output shaft dust deflector into the rear transfer output shaft sub-assembly.
Note
The rear transfer output shaft dust deflector should be installed completely.
INSTALL TRANSFER DRIVEN PINION
w/o Washer:
Using SST and a press, press the rear transfer output shaft sub-assembly into the transfer driven pinion.
Note
Do not apply stress to any parts of the transfer output shaft flange or transfer driven pinion other than the flat surfaces.
Secure the rear transfer output shaft sub-assembly in a vise between aluminum plates.
Note
Do not overtighten the vise.
Using a 30 mm socket wrench, install a new transfer gear nut to the rear transfer output shaft sub-assembly.
*1 | Washer |
w/ Washer:
Note
The front transfer driven pinion bearing service kit consists of a front transfer driven pinion bearing and washer.
Install the washer to the rear transfer output shaft sub-assembly as shown in the illustration.
Note
Install the washer in the correct direction.
*1 | Washer |
Using SST and a press, press the transfer driven pinion into the rear transfer output shaft sub-assembly.
Note
Do not apply stress to any parts of the transfer output shaft flange or transfer driven pinion other than the flat surfaces.
Secure the rear transfer output shaft sub-assembly in a vise between aluminum plates.
Note
Do not overtighten the vise.
Using a 30 mm socket wrench, temporarily tighten a new transfer gear nut to the rear transfer output shaft sub-assembly.
*a | 30 mm (1.18 in.) |
Using a dial indicator, measure the runout at the rear transfer output shaft sub-assembly flange.
Maximum runout |
---|
0.064 mm (0.00252 in.) |
If the runout is more than the maximum, remove and reinstall the rear transfer output shaft sub-assembly.
Using a dial indicator, measure the runout at the inner side of the rear transfer output shaft sub-assembly flange.
Maximum runout |
---|
0.063 mm (0.00248 in.) |
If the runout is more than the maximum, remove and reinstall the rear transfer output shaft sub-assembly.
Using a 30 mm socket wrench, fully tighten the transfer gear nut to the rear transfer output shaft sub-assembly.
INSTALL REAR TRANSFER OUTPUT SHAFT SUB-ASSEMBLY
*1 | O-ring |
Install a new O-ring to the front transfer driven pinion bearing.
Note
Do not scratch or twist the O-ring.
Firmly install the O-ring into the groove of the front transfer driven pinion bearing.
Install the rear transfer output shaft sub-assembly to the transfer case with the 5 bolts.
Note
Do not scratch or twist the O-ring.
INSPECT DRIVEN PINION PRELOAD
*1 | Nut |
Install a nut to the stud bolt.
Tech Tips
Use a nut that is used for installing the propeller shaft.
Using a torque wrench, check the driven pinion preload (starting torque) of the driven pinion.
Note
Measure the preload after rotating the bearing several times in the forward and backward directions to make sure the bearing is operating correctly.
Tech Tips
Install the torque wrench as shown in the illustration.
INSTALL TRANSFER RING GEAR
Uniformly apply a light coat of Prussian Blue on both sides of the transfer ring gear teeth.
Install the transfer ring gear to the transfer case.
INSTALL NO. 1 TRANSFER CASE COVER
Install the No. 1 transfer case cover to the transfer case with the 8 bolts.
ADJUST RING GEAR BACKLASH
Insert a dial indicator into the No. 2 transfer case plug hole, and place it perpendicular to the edge of a transfer ring gear tooth.
While securing the rear transfer output shaft sub-assembly by hand, rotate the transfer ring gear mounting case forward and backward by hand and measure the backlash of the transfer ring gear and transfer driven pinion.
Standard backlash |
---|
0.10 to 0.20 mm (0.00394 to 0.00787 in.) |
Note
Measure the ring gear at 3 or more locations.
If the result is not within the specified range, select a No. 1 ring gear mounting case washer (for backlash adjustment) and a No. 2 transfer ring gear mounting case washer (for preload adjustment) from the table below and reinstall them to bring the result within the specified range.
Tech Tips
If the backlash is small, select a thick washer for the No. 1 ring gear mounting case washer (for backlash adjustment) and a thin washer for the No. 2 transfer ring gear mounting case washer (for preload adjustment).
If the backlash is large, select a thin washer for the No. 1 ring gear mounting case washer (for backlash adjustment) and a thick washer for the No. 2 transfer ring gear mounting case washer (for preload adjustment).
No. 1 Ring Gear Mounting Case Washer (for backlash adjustment) | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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for K111F | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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No. 1 Ring Gear Mounting Case Washer (for backlash adjustment) | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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for U660F, U760F, EA64F, EB61F, EB63F, K114F | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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No. 2 Transfer Ring Gear Mounting Case Washer (for preload adjustment) | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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ADJUST TOTAL PRELOAD
*1 | Nut |
Install a nut to the stud bolt.
Tech Tips
Use a nut that is used for installing the propeller shaft.
Using a torque wrench, measure the total preload (starting torque) with the teeth of the driven pinion and ring gear in contact.
Total preload (starting torque) | ||||||
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Note
Measure the preload after rotating the bearing several times in the forward and backward directions to make sure the bearing is operating correctly.
Tech Tips
Install the torque wrench as shown in the illustration.
If the result is not within the specified range, select a No. 2 transfer ring gear mounting case washer (for preload adjustment) from the table below and reinstall it to bring the result within the specified range.
Tech Tips
If the preload is small, select a thick washer for the No. 2 transfer ring gear mounting case washer (for preload adjustment).
If the preload is large, select a thin washer for the No. 2 transfer ring gear mounting case washer (for preload adjustment).
No. 2 Transfer Ring Gear Mounting Case Washer (for preload adjustment) | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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ADJUST TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
Rotate the transfer output shaft sub-assembly several times in the forward and backward directions.
Remove the transfer ring gear and check the tooth contact.
*a | Proper Contact | *b | Heel Contact |
*c | Face Contact | *d | Select an adjusting washer that will shift the drive pinion closer to the ring gear (*b, *c) |
*e | Toe Contact | *f | Flank Contact |
*g | Select an adjusting washer that will shift the drive pinion away from to the ring gear (*e, *f) | - | - |
Note
Check the tooth contact at 4 or more locations on the transfer ring gear.
When replacing washers (adjusting the backlash, preload or tooth contact pattern), reapply a coat of Prussian Blue.
Tech Tips
The Prussian Blue pattern indicates the tooth contact points.
In instances of face contact or flank contact, perform the following procedure.
Move and adjust the transfer ring gear using the No. 2 transfer ring gear mounting case washer (for preload adjustment) and the No. 1 ring gear mounting case washer (for backlash adjustment).
In instances of heel contact or toe contact, perform the following procedure.
Select a transfer output shaft washer (for tooth contact adjustment) from the table below, and move and adjust the transfer driven pinion.
Transfer Output Shaft Washer (for tooth contact adjustment) | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
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If the tooth contact has been adjusted, recheck the backlash, preload and tooth contact pattern.
REMOVE NO. 1 TRANSFER CASE COVER
Remove the 8 bolts and No. 1 transfer case cover from the transfer case.
REMOVE TRANSFER RING GEAR
Remove the transfer ring gear from the transfer case.
REMOVE REAR TRANSFER OUTPUT SHAFT SUB-ASSEMBLY
Remove the 5 bolts and rear transfer output shaft sub-assembly from the transfer case.
INSTALL TRANSFER CASE STRAIGHT PIN
Using a plastic-faced hammer, install straight pins to the locations shown in the illustration.
*A | for K111F | *B | for U660F, U760F, EA64F, EB61F, EB63F, K114F |
Drive in depth (A) |
---|
10.8 to 11.8 mm (0.426 to 0.464 in.) |
Drive in depth (B) |
---|
6.5 to 7.5 mm (0.256 to 0.295 in.) |
INSTALL REAR TRANSFER OUTPUT SHAFT SUB-ASSEMBLY
Secure the rear transfer output shaft sub-assembly in a vise between aluminum plates.
Note
Do not overtighten the vise.
Using a chisel and hammer, stake the transfer gear nut.
Note
Fully stake the transfer gear nut along the entire groove.
Install the rear transfer output shaft sub-assembly to the transfer case with the 5 bolts.
Note
Do not scratch, twist or break the O-ring.
INSTALL TRANSFER RING GEAR
Install the transfer ring gear to the transfer case.
INSTALL NO. 1 TRANSFER CASE COVER
Using a scraper, clean the seal packing from the transfer case and No. 1 transfer case cover and remove any oil using a cleaning solvent.
Note
Do not scratch the installation area.
*1 | Seal Packing |
*a | Seal Width 2.0 to 3.0 mm (0.0788 to 0.118 in.) |
Apply seal packing to the transfer case as shown in the illustration.
Seal packing |
---|
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent |
Note
Install the cover to the case within 10 minutes of application.
Start the application from inside the area marked A.
Overlap the seal packing at least 10 mm (0.394 in.) at the beginning and the end of application.
Install the No. 1 transfer case cover with the 8 bolts.
INSTALL TRANSFER CASE OIL SEAL
Using SST and a hammer, tap in a new transfer case oil seal as shown in the illustration.
*A | for K111F | *B | for U660F, U760F, EA64F, EB61F, EB63F, K114F |
*1 | Transfer Case Oil Seal | - | - |
Drive in depth (A) |
---|
9.5 to 10.5 mm (0.375 to 0.413 in.) |
Note
Tap the transfer case oil seal uniformly so that the transfer case oil seal is straight.
Do not tap the transfer case oil seal in too far.
INSTALL TRANSFER CASE OIL SEAL RH
*1 | Transfer Case Oil Seal RH |
Using SST and a hammer, tap in a new transfer case oil seal RH as shown in the illustration.
Drive in depth (A) |
---|
7.5 to 8.5 mm (0.296 to 0.334 in.) |
Note
Tap the transfer case oil seal RH uniformly so that the transfer case oil seal RH is straight.
Do not tap the transfer case oil seal RH in too far.
INSTALL TRANSFER CASE BREATHER PLUG
Using SST, tap in a new transfer case breather plug until it meets the transfer case.
INSTALL NO. 2 TRANSFER CASE PLUG
*A | for K111F |
*B | for U660F, U760F, EA64F, EB61F, EB63F, K114F |
Using a 10 mm socket hexagon wrench, install a new gasket and the No. 2 transfer case plug (filler plug).
INSTALL TRANSFER DRAIN PLUG
*A | for K111F |
*B | for U660F, U760F, EA64F, EB61F, EB63F, K114F |
Using a 10 mm socket hexagon wrench, install a new gasket and the transfer drain plug.
INSTALL NO. 1 TRANSFER CASE PLUG
Install a new gasket and the No. 1 transfer case plug.
REMOVE TRANSFER ASSEMBLY
*A | for K111F |
*B | for U660F, U760F, EA64F, EB61F, EB63F, K114F |
Remove the transfer assembly from the overhaul attachment.
INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT
Clean the bolt holes.
*A | for K111F |
*B | for U660F, U760F, EA64F, EB61F, EB63F, K114F |
*a | Transfer Side |
*b | Toyota Genuine Adhesive 1324 |
Using 2 nuts, install the 4 stud bolts in the locations shown in the illustration.
Note
Install the shorter threaded part of each stud bolt to the transfer side.