Reassembly

MF1A TRANSFER / 4WD / AWD: TRANSFER ASSEMBLY: REASSEMBLY

1. INSTALL TRANSFER DRIVEN PINION REAR BEARING

(a) Using SST and a press, press the driven pinion rear bearing (outer race) into the case.

SST : 09950-60010

09951-00620

SST : 09950-70010

09951-07150

NOTICE:
Keep the transfer case horizontal using wooden blocks, etc.

(b) Apply gear oil to the driven pinion rear bearing (outer race).

2. INSTALL TRANSFER OUTPUT SHAFT WASHER

(a) Install the transfer output shaft washer to the transfer case.

HINT
Install the same washer as the one removed.

(b) Apply gear oil to the transfer output shaft washer.

3. INSTALL TRANSFER DRIVEN PINION FRONT BEARING

(a) Apply gear oil to the inner surface of the transfer case.

Text in Illustration

(b) Using SST, install the transfer driven pinion front bearing (outer race) to the transfer case.

SST : 09950-60010

09951-00610

09951-00620

09951-00650

SST : 09950-60020

09951-00680

(c) Using SST and a press, press the driven pinion front bearing (inner race) into the driven pinion.

SST : 09506-30012

4. INSTALL DRIVEN PINION

(a) Install the driven pinion to the transfer case.

(b) Install a new transfer pinion bearing spacer and driven pinion rear bearing (inner race) to the driven pinion.

HINT
Install the pinion bearing spacer with the larger inner diameter facing forward as shown in the illustration.

(c) Using SST, install a new gear nut.

SST : 09326-20011

SST : 09556-16030

Reference without SST - Torque : 270 to 420 Nm (2754 to 4282 kgf-cm, 199 to 308 ft-lbf)

Reference with SST - Torque : 255 to 396 Nm (2601 to 4038 kgf-cm, 188 to 291 ft-lbf)

NOTICE:
* The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).
* The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 840 mm (2.8 ft.) Service Precautions.
* The "with SST" torque value is effective when SST is parallel to the torque wrench.
* Do not stake the nut until the final preload, tooth contact and backlash adjustments are completed.

5. ADJUST DRIVEN PINION PRELOAD

(a) Using SST and a torque wrench, measure the driven pinion preload.

SST : 09326-20011

Preload (at Starting):

NOTICE:
* The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).
* The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.) Service Precautions.
* The "with SST" torque value is effective when SST is parallel to the torque wrench.
* If the preload is more than the specification, replace the pinion bearing spacer with a new one.
* If the preload is not sufficient, adjust the driven pinion by tightening the lock nut 5° to 10° and measuring the preload until the preload is within the specification.
* Even if the tightening torque of the gear nut exceeds the specified torque, if the preload is insufficient, loosen the gear nut once and apply rust preventive oil or hypoid gear oil to the gear nut and to the screw or bearing surface of the driven pinion. Then perform the procedure again. If the tightening torque is less than the specified torque, replace the pinion bearing spacer with a new one and adjust it.
* Do not loosen the gear nut to reduce the preload.

6. INSTALL RING GEAR

(a) Clean the contact surface of the ring gear and transfer ring gear mounting case.

(b) Heat the ring gear in boiling water.

(c) Carefully remove the ring gear from the boiling water.

(d) After the moisture on the ring gear has completely evaporated, quickly align the matchmarks and set the ring gear onto the transfer ring gear mounting case.

Text in Illustration

(e) Apply adhesive to the 12 bolts.

Sealant:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(f) Install the 12 bolts.

Torque : 99 Nm (1005 kgf-cm, 72 ft-lbf)

NOTICE:
* Tighten the bolts evenly in a diagonal pattern using several steps.
* Tighten the bolts after the ring gear has cooled down sufficiently.
* In order to ensure proper sealing of the bolts, apply adhesive to the bolts and install them within 10 minutes of adhesive application.

7. INSTALL RING GEAR MOUNTING CASE BEARING

(a) Using SST and a press, press the ring gear mounting case bearing (inner race) RH into the transfer ring gear mounting case.

SST : 09950-60010

09951-00420

(b) Install the ring gear mounting case bearing (outer race) RH to the transfer ring gear mounting case.

(c) Apply gear oil to the ring gear mounting case bearing RH.

(d) Using SST and a press, press the ring gear mounting case bearing (inner race) LH into the transfer ring gear mounting case.

SST : 09223-00010

SST : 09726-40010

(e) Install the ring gear mounting case plate washer to the case.

HINT
Use a new washer with the same thickness as the one removed when installing the bearing.

(f) Using SST and a press, press the ring gear mounting case bearing (outer race) LH into the transfer case.

SST : 09950-60010

09951-00620

SST : 09950-70010

09951-07200

(g) Apply gear oil to the ring gear mounting case bearing.

8. INSTALL TRANSFER RING GEAR MOUNTING CASE

(a) Apply gear oil to the transfer ring gear mounting case.

(b) Install the transfer ring gear mounting case to the transfer case.

9. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER

(a) Align the cutout on the No. 1 transfer output shaft spacer with the transfer case hole to install it as shown in the illustration.

10. INSTALL NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER

(a) Using a brass bar and a hammer, install the No. 2 transfer ring gear mounting case washer.

HINT
Use the No. 2 washer with the same thickness as the one removed.

11. INSTALL BEARING CAP

(a) Install the bearing cap with the 2 bolts.

Torque : 63 Nm (644 kgf-cm, 47 ft-lbf)

12. INSPECT RING GEAR BACKLASH

(a) Set a dial indicator perpendicular to a ring gear tooth tip. Secure the driven pinion in place and move the ring gear back and forth to measure the backlash.

Backlash:

0.14 to 0.25 mm (0.00551 to 0.00984 in.)

NOTICE:
Check at least 3 positions on the circumference of the ring gear.

(b) If the backlash is outside the specified range, select a ring gear mounting case bearing LH side washer from the table below and install it to meet the specified range.

Text in Illustration

Washer Thickness

13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION

(a) Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.

(b) Rotate the ring gear 10 times or more.

(c) Rotate the ring gear to inspect the tooth contact pattern.

(d) If the tooth contact pattern is not correct, select a new transfer output shaft washer that is thicker or thinner as necessary and recheck.

Text in Illustration

Washer Thickness

NOTICE:
When the washer thickness is changed, readjust the backlash MF1A Transfer Case.

14. INSPECT AND ADJUST TOTAL PRELOAD

(a) Using SST and a torque wrench, measure the total preload.

SST : 09326-20011

Total Preload (at Starting):

Text in Illustration

Washer Thickness

(b) Using a chisel and a hammer, stake the gear nut.

15. INSTALL TRANSFER CASE FRONT OIL SEAL (for RH Side)

(a) Using SST and a hammer, drive a new transfer case front oil seal into the case until it reaches the position shown in the illustration.

SST : 09950-60010

09951-00350

09951-00580

09952-06010

SST : 09950-70010

09951-07150

Drive in depth:

33.5 to 34.5 mm (1.32 to 1.36 in.)

NOTICE:
Make sure that the oil seal is not tilted.

(b) Apply a small amount of MP grease to the lip of the transfer case front oil seal.

16. INSTALL TRANSFER CASE FRONT OIL SEAL

(a) Using SST and a hammer, drive a new transfer case front oil seal into the transfer case until it reaches the position shown in the illustration.

SST : 09608-10010

SST : 09950-70010

09951-07150

Drive in depth:

9.5 to 10.5 mm (0.374 to 0.413 in.)

(b) Apply a small amount of MP grease to the lip of the transfer case front oil seal.

17. INSTALL TRANSFER CASE REAR OIL SEAL

(a) Using SST and a hammer, drive a new transfer case rear oil seal into the extension housing until it reaches the position shown in the illustration.

SST : 09325-20010

Drive in depth:

1.1 to 1.9 mm (0.0433 to 0.0748 in.)

(b) Apply a small amount of MP grease to the lip of the transfer case rear oil seal.

18. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR

(a) Using SST and a press, press in the extension housing dust deflector until it contacts the installation surface as shown in the illustration.

SST : 09950-60020

09951-00810

SST : 09950-70010

09951-07150

19. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY

(a) Remove any FIPG material and be careful not to drop oil on the contact surfaces of the transfer extension housing sub-assembly and the transfer case.

(b) Degrease the surfaces with a non-residue solvent.

(c) Apply FIPG to the transfer extension housing sub-assembly.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(d) Install the transfer extension housing sub-assembly with the 4 bolts to the transfer case.

Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)

NOTICE:
Assemble the transfer extension housing sub-assembly within 10 minutes of FIPG application.

20. SEPARATE TRANSFER ASSEMBLY

(a) Remove the transfer assembly from the overhaul attachment.

21. INSTALL TRANSFER CASE STRAIGHT PIN

(a) Using a plastic hammer, drive the 4 transfer case straight pins into the transfer case at the positions shown in the illustration.

Text in Illustration

22. INSTALL TRANSFER CASE BREATHER PLUG

(a) Using SST and a hammer, tap in a new breather plug.

SST : 09612-10093

09612-10061

23. INSTALL BREATHER OIL DEFLECTOR

(a) Install the breather oil deflector with the bolt.

Torque : 6.5 Nm (66 kgf-cm, 58 in-lbf)

24. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY

(a) Remove any FIPG material and be careful not to drop oil on the contact surfaces of the transfer case cover sub-assembly and the transfer case.

(b) Degrease the surfaces with a non-residue solvent.

(c) Apply FIPG to the transfer case cover sub-assembly.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(d) Install the transfer case cover sub-assembly with the 6 bolts.

Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

NOTICE:
* Wait for at least 1 hour after installing the transfer case cover sub-assembly before adding transfer oil.
* Assemble the transfer case cover sub-assembly within 10 minutes after the FIPG application.

(e) Install the transfer case cover sub-assembly with the new 2 bolts.

Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

25. INSTALL TRANSFER DRAIN PLUG

(a) Install a new gasket to the transfer drain plug.

(b) Install the transfer drain plug to the transfer assembly.

Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)

26. INSTALL NO. 1 TRANSFER CASE PLUG

(a) Install a new gasket to the No. 1 transfer case plug.

(b) Install the No. 1 transfer case plug to the transfer assembly.

Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)

27. INSTALL NO. 2 TRANSFER CASE PLUG

(a) Install a new gasket to the No. 2 transfer case plug.

(b) Install the No. 2 transfer case plug to the transfer assembly.

Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)

28. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT

(a) Install the 4 new transfer and transaxle setting stud bolts to the transfer case positions shown in the illustration.

Text in Illustration

Stud bolt length:

a
30 mm (1.1811 in.)

b
12 mm (0.4724 in.)

c
22 mm (0.8661 in.)

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

NOTICE:
Install the sealed side of the stud bolt to the transfer.