Transfer.pdf

7/29/2019 Transfer.pdf

1/51

TR06J-02

D04344

Front DriveGear Piece

S Snap Ring

Front TaperRoller Bearing

Needle Roller Bearing

Clutch Hub

High Speed OutputGear BushingHigh Speed

Output Gear

Rear TaperRoller Bearing

x12

DifferentialRear Case

Pinion Shaft

Rear SideGear

: Specified torque

Thrust Washer

Front Side Gear

Nm (kgfcm, ftlbf)

Straight Pin

Low GearStraight Pin

High and LowClutch Sleeve

Thrust WasherThrust Washer

Thrust Washer

S Non-reusable part

Pinion Gear

DifferentialFront Case

See page TR-31

Pinion Gear

-TRANSFER CENTER DIFFERENTIAL

TR-27

1915Author: Date:

2004 LAND CRUISER (RM1071U)

CENTER DIFFERENTIAL

COMPONENTS
http://../04rmsour/2004/04cruise/tr/cendif/reas.pdfhttp://../04rmsour/2004/04cruise/tr/cendif/reas.pdf


2/51

TR06K-02

TF0900

TF0944

Q07101

SST

Q07102

SST

D02679

TR-28-TRANSFER CENTER DIFFERENTIAL

1916Author: Date:


DISASSEMBLY1. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND

THRUST CLEARANCE

(a) Using a feeler gauge, measure the high speed output

gear thrust clearance.

Standard clearance:

0.10 - 0.25 mm (0.0039 - 0.0098 in.)

Maximum clearance:

0.25 mm (0.0098 in.)

(b) Using a dial indicator, measure the high speed output

gear radial clearance.

Standard clearance:

0.035 - 0.091 mm (0.00138 - 0.00358 in.)

Maximum clearance:

0.091 mm (0.00358 in.)

2. REMOVE FRONT DRIVE GEAR PIECE

(a) Using a snap ring expander, remove the snap ring.

(b) Using SST and a press, remove the front drive gear piece.

SST 09950-00020, 09950-60010 (09951-00320)

NOTICE:

Be careful not to drop the center differential assembly.

3. REMOVE FRONT TAPER ROLLER BEARING

Using SST and a press, remove the front taper roller bearing.

SST 09950-00020

NOTICE:

Set the claw of SST to the bearing inner race securely.

4. REMOVE HIGH SPEED OUTPUT GEAR

5. REMOVE 2 NEEDLE ROLLER BEARINGS


3/51

D02680

Q07103

SST

Q07113

SST

D02681

D02682


TR-29

1917Author: Date:


6. REMOVE HIGH AND LOW CLUTCH SLEEVE

7. REMOVE HIGH SPEED OUTPUT GEAR BUSHING

AND CLUTCH HUB

(a) Using SST, remove the high speed output gear bushing

and clutch hub.

SST 09950- 00020, 09950- 00030, 09950- 60010

(09951-00320)(b) Using a magnetic finger, remove the straight pin from the

differential front case.

8. REMOVE REAR TAPER ROLLER BEARING

Using SST and a press, remove the rear taper roller bearing.

SST 09950-00020, 09950-60010 (09951-00320)

NOTICE:


9. REMOVE DIFFERENTIAL REAR CASE

Remove the 12 bolts and differential rear case.

10. REMOVE THRUST WASHER AND REAR SIDE GEAR


4/51

D02683

D02684

D02685

D02686


1918Author: Date:


11. REMOVE PINION SHAFT, 2 PINION GEARS AND 2

THRUST WASHERS

(a) Remove the straight pin from the pinion shaft.

(b) Remove the pinion shaft, 2 pinion gears and thrust wash-

ers.

(c) Remove the front side gear and thrust washer.

12. REMOVE LOW GEAR

Using a plastic hammer, tap and remove the low gear.

NOTICE:

Be careful not to damage the low gear.


5/51

TR06L-02

D02687

TF1012

TF0913


TR-31

1919Author: Date:


REASSEMBLYHINT:

Coat all of the sliding and rotating surfaces with gear oil before

reassembly.

1. INSTALL LOW GEAR

(a) Clean the contact surface of the differential case.

(b) Heat the low gear in boiling water.

(c) Carefully remove the low gear from the water.

(d) After the moisture on the low gear has completely evapo-

rated, quickly install the low gear to the differential case.

2. INSTALL THRUST WASHER AND FRONT SIDE GEAR

3. INSTALL PINION SHAFT, 2 PINION GEARS AND 2

THRUST WASHERS

(a) Install the pinion shaft, 2 pinion gears and thrust washers

to the differential front case.


6/51

TF0917

TF0920

Q00534

SST

Q00547

SST

SST


1920Author: Date:


(b) Using a dial indicator, measure the front case backlash.

HINT:

Push the pinion shaft.

Maximum backlash: 0.05 mm (0.0020 in.)

If the backlash is not within the specification, replace the thrust

washer with one of the correct size and reinstall the thrust wash-er.

Thickness mm (in.) Thickness mm (in.)

1.70 (0.0669) 2.45 (0.0965)

1.85 (0.0728) 2.60 (0.1024)

2.00 (0.0787) 2.75 (0.1083)

2.15 (0.0846) 2.90 (0.1142)

2.30 (0.0906) 3.05 (0.1201)

(c) In the same way, measure the rear case backlash.

4. INSTALL STRAIGHT PIN TO PINION SHAFT

5. INSTALL REAR SIDE GEAR AND THRUST WASHER

6. INSTALL DIFFERENTIAL REAR CASE

(a) Install the differential rear case and 12 set bolts.

Torque: 88 Nm (900 kgfcm, 65 ftlbf)

(b) Turn the pinion gear.

(c) Loosen the 12 rear case set bolts.

(d) Torque the 12 rear case set bolts.

Torque: 98 Nm (1,000 kgfcm, 72 ftlbf)

7. INSTALL REAR TAPER ROLLER BEARING

Using SST and a press, install the rear taper roller bearing.

SST 09316-12010

8. INSTALL CLUTCH HUB

Using SST and a press, install the clutch hub.

SST 09316-12010, 09316-60011 (09316-00011)


7/51

Q00549

D04312

Pin

Groove

SST

Q00555

Q00539

SST

SST


TR-33

1921Author: Date:


9. INSTALL HIGH SPEED OUTPUT GEAR BUSHING

(a) Apply MP grease to the straight pin.

(b) Install the straight pin, as shown.

(c) Using SST and a press, install the high speed output gear

bushing.

SST 09316-12010, 09316-60011 (09316-00011)

NOTICE:

Before pressing on the differential front case, align the

groove on the bushing with the pin on the shaft.

10. INSTALL HIGH AND LOW CLUTCH SLEEVE

HINT:

Make sure to install the high and low clutch sleeve in the correct

direction.

11. INSTALL NEEDLE ROLLER BEARING AND HIGH

SPEED OUTPUT GEAR

(a) Apply gear oil to the needle roller bearing.(b) Install the needle roller bearing and high speed output

gear.

12. INSTALL FRONT TAPER ROLLER BEARING

Using SST and a press, install the front taper roller bearing.

SST 09316-12010, 09316-60011 (09316-00011)


8/51

Q00540

SST

SST

TF0931


1922Author: Date:


13. INSTALL FRONT DRIVE GEAR PIECE

Using SST and a press, install the front drive gear piece.

SST 09316-12010, 09316-60011 (09316-00011)

14. INSTALL SNAP RING

(a) Select a snap ring that will allow the minimum axial play.

Mark Thickness mm (in.) Mark Thickness mm (in.)

A 2.00 (0.0787) G 2.60 (0.1024)

B 2.10 (0.0827) H 2.70 (0.1063)

C 2.20 (0.0866) J 2.80 (0.1102)

D 2.30 (0.0906) K 1.80 (0.0709)

E 2.40 (0.0945) L 1.90 (0.0748)

F 2.50 (0.0984) - -

(b) Using a snap ring expander, install a new snap ring.

15. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND

THRUST CLEARANCE (See page TR-28 )
http://../04rmsour/2004/04cruise/tr/cendif/disa.pdfhttp://../04rmsour/2004/04cruise/tr/cendif/disa.pdf


9/51

TR06M-02

Z18836

Front Output Shaft

Dust Deflector

Oil Seal

Front Extension Housing

Ball Bearing

Snap Ring

Drive Clutch Hub

Snap Ring

Non-reusable part

-TRANSFER FRONT EXTENSION HOUSING

TR-35

1923Author: Date:


FRONT EXTENSION HOUSING

COMPONENTS


10/51

Q07133

SST

TR06N-03

TF1036

D02660

SST

TF0937

TF0938

TR-36


1924Author: Date:


DISASSEMBLY1. REMOVE DRIVE CLUTCH HUB


(b) Using SST, remove the drive clutch hub.

SST 09950- 40011 (09951- 04020, 09952- 04010,

09953- 04030, 09954- 04020, 09955- 04021,

09957-04010, 09958-04011)

2. REMOVE FRONT OUTPUT SHAFT

Using a plastic hammer, drive out the front output shaft.

3. REMOVE DUST DEFLECTOR

(a) Using SST, remove the dust deflector.

SST 09950- 40011 (09951- 04020, 09952- 04010,

09953- 04030, 09954- 04010, 09955- 04051,

09957-04010, 09958-04011)

(b) Using a screwdriver and hammer, tap the dust deflector

and remove it from the extension housing.

4. REMOVE OIL SEAL

Using a screwdriver, pry out the oil seal from the front extension

housing.


11/51

TF0939

TF0940

SST


TR-37

1925Author: Date:


5. REMOVE BALL BEARING

(a) Using a screwdriver, remove the snap ring.

(b) Using SST and a press, remove the ball bearing.

SST 09316-6001 1 (09316-00011, 09316-00071)


12/51

TR06O-02

TF1058

TF0967

SST

TF0943

SST

TF0939

TF0945

SST

TR-38


1926Author: Date:


REASSEMBLYHINT:


reassembly.

1. INSTALL DUST DEFLECTOR

(a) Using a plastic hammer, install a new dust deflector to the

front extension housing.

(b) Using SST and a press, install a new dust deflector to the

front output shaft.

SST 09316-2001 1, 09316-60011 (09316-00011)

2. INSTALL BALL BEARING

(a) Using SST and a press, install the ball bearing to the front

extension housing.

SST 09316-6001 1 (09316-00011, 09316-00031)

(b) Select a snap ring that will allow the minimum axial play.

Mark Thickness mm (in.)

A 1.70 (0.0669)

B 1.80 (0.0709)

(c) Using a screwdriver, install a new snap ring.

3. INSTALL OIL SEAL

(a) Apply MP grease to the lip of a new oil seal.

(b) Using SST and a hammer, drive in a new oil seal to the

front extension housing.

SST 09316-6001 1 (09316-00011, 09316-00061)


13/51

Q00542

SST

SST

TF0933


TR-39

1927Author: Date:


4. INSTALL FRONT OUTPUT SHAFT AND DRIVE

CLUTCH HUB

(a) Using SST and a press, install the front output shaft and

drive clutch hub.

SST 09316-2001 1, 09316-60011 (09316-00011,

09316-00041, 09316-00071)



A 1.80 (0.0709)

B 1.90 (0.0748)

C 2.00 (0.0787)

D 2.10 (0.0827)

E 2.20 (0.0866)

(c) Using a snap ring expander, install a new snap ring.


14/51

TR06F-02

Z15264

Front Taper RollerBearing Idler Gear

High and Low Clutch Sleeve

Needle Roller Bearing

Idler Low Gear

Rear TaperRoller Bearing

TR-22

-TRANSFER IDLER GEAR

1910Author: Date:


IDLER GEAR

COMPONENTS


15/51

TF0887

TR06G-03

TF0888

D02888

SST

Q07100

SST

Socket Wrench

D02674


TR-23

1911Author: Date:


DISASSEMBLY1. INSPECT IDLER LOW GEAR RADIAL AND THRUST

CLEARANCE

(a) Using a feeler gauge, measure the idler low gear thrust

clearance.

Standard clearance:

0.125 - 0.275 mm (0.00492 - 0.01083 in.)

Maximum clearance:

0.275 mm (0.01083 in.)

(b) Using a dial indicator, measure the idler low gear radial

clearance.

Standard clearance:

0.015 - 0.068 mm (0.00059 - 0.00268 in.)

Maximum clearance:

0.068 mm (0.00268 in.)

2. REMOVE FRONT TAPER ROLLER BEARING

Using SST, remove the front taper roller bearing.

SST 09950- 40011 (09951- 04010, 09952- 04010,

09953- 04030, 09954- 04010, 09955- 04061,

09957- 04010, 09958- 04011), 09950- 60010

(09951-00330)

NOTICE:


3. REMOVE REAR TAPER ROLLER BEARING

Using SST, a press and socket wrench, remove the rear taper

roller bearing.

SST 09950-00020

NOTICE:


4. REMOVE IDLER LOW GEAR AND NEEDLE ROLLER

BEARING FROM IDLER GEAR


16/51

D02675

TR-24-TRANSFER IDLER GEAR

1912Author: Date:


5. REMOVE HIGH AND LOW CLUTCH SLEEVE FROM

IDLER GEAR


17/51

TR06H-02

D02676

D02677


TR-25

1913Author: Date:


INSPECTION1. INSPECT IDLER GEAR

Using a micrometer, measure the idler gear diameter.

Standard diameter:

38.48 - 38.50 mm (1.5149 - 1.5157 in.)

Maximum diameter:

38.50 mm (1.5157 in.)

2. INSPECT IDLER LOW GEAR

Using a cylinder gauge, measure the idler low gear diameter.

Standard diameter:

45.52 - 45.54 mm (1.7922 - 1.7930 in.)

Maximum diameter:

45.54 mm (1.7930 in.)


18/51

TR06I-02

TF0893

SST

Q00538

D02678

TF0896

SST

TR-26-TRANSFER IDLER GEAR

1914Author: Date:


REASSEMBLYHINT:


reassembly.

1. INSTALL FRONT TAPER ROLLER BEARING

Using SST and a press, install the front taper roller bearing.

SST 09316-6001 1 (09316-00011, 09316-00031)

2. INSTALL HIGH AND LOW CLUTCH SLEEVE

HINT:

Make sure to install the high and low clutch sleeve in the correct

direction.

3. INSTALL NEEDLE ROLLER BEARING AND IDLER

LOW GEAR TO IDLER GEAR

(a) Apply gear oil to the needle roller bearing.

(b) Install the needle roller bearing and idler low gear.

4. INSTALL REAR TAPER ROLLER BEARING

Using SST and a press, install the rear taper roller bearing.

SST 09316-6001 1 (09316-00011, 09316-00071)

5. INSPECT IDLER LOW GEAR RADIAL AND THRUST

CLEARANCE (See page TR-25 )
http://../04rmsour/2004/04cruise/tr/idrgea/insp.pdfhttp://../04rmsour/2004/04cruise/tr/idrgea/insp.pdf


19/51

TR06C-02

D02654

S Snap Ring

S Front Ball Bearing

Input Shaft

Rear Ball Bearing

S Non-reusable part

S Snap Ring

-TRANSFER INPUT SHAFT

TR-19

1907Author: Date:


INPUT SHAFT

COMPONENTS


20/51

D02691

TR06D-03

D02853

Socket Wrench

D02655

SST

TR-20


1908Author: Date:


DISASSEMBLY1. REMOVE REAR BALL BEARING


(b) Using a socket wrench and press, remove the rear ball

bearing.

2. REMOVE FRONT BALL BEARING


(b) Using SST, remove the front ball bearing.

SST 09950- 40011 (09951- 04020, 09952- 04010,

09953- 04030, 09954- 04010, 09955- 04011,

09957- 04010, 09958- 04011), 09950- 60010

(09951-00400)


21/51

TR06E-02

D02656

SST

D02657

D02658

SST

D02659


TR-21

1909Author: Date:


REASSEMBLYHINT:


reassembly.

1. INSTALL FRONT BALL BEARING

(a) Using SST and a press, install a new front ball bearing.

SST 09316-6001 1 (09316-00011)



A 2.90 (0.1141) D 3.05 (0.1201)

B 2.95 (0.1161) E 3.10 (0.1220)

C 3.00 (0.1181) F 3.15 (0.1240)


2. INSTALL REAR BALL BEARING

(a) Using SST and a press, install the rear ball bearing.

SST 09316-6001 1 (09316-00011, 09316-00031)



A 2.00 (0.0787)

B 2.10 (0.0827)

C 2.20 (0.0866)

D 2.30 (0.0906)E 2.40 (0.0945)



22/51

D02866

ON OFF

TR06V-02

D02867

LN

H

Z15367

Relay side:

-TRANSFER MOTOR SHIFT CONTROL SYSTEM

TR-49

1937Author: Date:


INSPECTION1. INSPECT SWITCH POSITION

(a) Start the engine, and shift the transfer shift lever to the H

position.

(b) Check that the center diff. indicator light comes on when

the the switch is in ON position. Check that the light goes

off when the switch is in OFF position.

2. INSPECT SHIFT LEVER POSITION

(a) Start the engine, and turn the center diff. lock switch to

OFF.

(b) Check that the center diff. indicator light comes on when

the transfer shift lever is shifted to the L position. Check

that the light goes off when the lever is shifted to the Nor H position.

3. INSPECT CENTER DIFF. LOCK CONTROL RELAY

(a) Check that continuity exists between each terminal, as

shown in the chart.

Tester connected terminal number Specified condition

1 - 2 Continuity

2 - 4 Continuity

6 - 7 *

*: There is a diode between the terminals 6 and 7.

If no continuity exists, check that continuity exists when chang-

ing the position of probe for the position of negative probe

of tester.

(b) Apply battery positive voltage between each terminal and

check that continuity exists between each terminal, as

shown in the chart.

Battery voltage

applied terminal

Tester connected terminal

number

Specified condition

6 (+) - 5 (-)1 - 3

1 - 2

Continuity

No continuity

7 (+) - 2 (-) 9 - 10 No continuity

9 (+) - 10 (-)3 - 4

2 - 4

Continuity

No continuity

If continuity is not as specified, replace the relay.


23/51

D02869

1

2

4

3

5

1

4

3

5

2

1

12345

2345

Free Lock

Lock Free

D04311

Heater main relay:

1

4

2

5

3

1

2

3

45

*

*: Relay housingmetallic parts

D02663

Motor actuator side:

TR-50-TRANSFER MOTOR SHIFT CONTROL SYSTEM

1938Author: Date:


4. INSPECT ACTUATOR OPERATION

(a) Raise up the front wheels, place the stopper under the

rear wheels to block them, and pull up the parking brake.

(b) Disconnect the connector of the actuator and connect it

to the relay using wire.

(c) Check that the front propeller shaft can be rotated byhand.

Inspection Item Standard

Center Diff.

Free LockFront propeller shaft cannot be rotated.

Center Diff.

Lock FreeFront propeller shaft can be rotated.

HINT:

When inspecting the operation described above, use a heater

main relay.

NOTICE:

Connect the terminals being careful not to touch the neigh-

boring terminals or metallic parts of relay housing.

5. INSPECT MOTOR ACTUATOR (MOTOR)

(a) Remove the motor actuator (See page TR-8 ).

(b) Measure the resistance between the terminals 1 and 5.

Standard resistance: 0.3 - 100

(c) Measure the resistance between the terminals 1 or 5 and

body ground.

Standard resistance: More than 0.5 MIf the resistance value is not as specified, replace the motor ac-

tuator.
http://../04rmsour/2004/04cruise/tr/traass/disa.pdfhttp://../04rmsour/2004/04cruise/tr/traass/disa.pdf


24/51

D02877

1

2

3

D02665

ON-OFF

270.82mm

Ball


TR-51

1939Author: Date:


6. INSPECT CENTER DIFF. LOCK SWITCH CONTINUITY

(a) Remove the center diff. lock switch (See page AC-102 ).

(b) Inspect the continuity between each terminal.

Center diff. lock switch

condition

Tester connected terminal

numberSpecified condition

ON

1 - 2

1 - 3

2 - 3

No continuity

No continuity

Continuity

OFF

1 - 2

1 - 3

2 - 3

Continuity

No continuity

No continuity

7. INSPECT TRANSFER INDICATOR SWITCH CONTINU-

ITY

(a) Remove the 3 transfer indicator switches (See page

TR-8 ).

(b) Check that continuity exists between terminals 1 and 2

when pushing the ball at the tip of the switch.
http://../04rmsour/2004/04cruise/ac/acca/disa.pdfhttp://../04rmsour/2004/04cruise/tr/traass/disa.pdfhttp://../04rmsour/2004/04cruise/tr/traass/disa.pdfhttp://../04rmsour/2004/04cruise/ac/acca/disa.pdf


25/51

TR06U-02

D03520

Center Diff. Lock Switch

Center Diff. Lock Indicater Light

Transfer Indicator Switch(Center Diff. Lock)

Motor Actuator

Transfer Indicator Switch(Low Switch)

Center Diff. LockControl Relay

Transfer Indicator Switch(Neutral Switch)

TR-48


1936Author: Date:


MOTOR SHIFT CONTROL SYSTEM

LOCATION


26/51

TR06P-02

D04346

BallBearing

Dust Deflector Seal Ring

Rear Output Shaft

S Screw PlugBall

Rear Extension Housing

Driven Rotor

Speed Sensor Drive Gear

Drive Rotor

Oil Pump CoverSpring

Valve Seat

4.9 (50, 43 in.lbf)

29 (300, 22)

Oil Seal

Snap Ring

Snap Ring

Oil PumpDrive Shaft

Oil Pump Plate

Nm (kgfcm, ftlbf) : Specified torque

Non-reusable part

S Precoated part

4.9 (50, 43 in.lbf)

TR-40-TRANSFER REAR EXTENSION HOUSING

1928Author: Date:


REAR EXTENSION HOUSING

COMPONENTS


27/51

TR06Q-02

TF1039

Q00530

TF1033

TF1034

Q08384

-TRANSFER REAR EXTENSION HOUSING

TR-41

1929Author: Date:


DISASSEMBLY1. REMOVE OIL PUMP DRIVE SHAFT

2. REMOVE OIL PUMP COVER

(a) Using a torx socket wrench (T30), remove the 3 screws.

(b) Install the 2 suitable bolts to the pump cover.

(c) Remove the pump cover from the rear extension housing.

3. REMOVE DRIVE ROTOR FROM DRIVEN ROTOR

4. REMOVE DRIVEN ROTOR FROM REAR EXTENSION

HOUSING

5. REMOVE SCREW PLUG, SPRING, BALL AND VALVE

SEAT

(a) Using a hexagon wrench, remove the screw plug.

(b) Using a magnetic finger, remove the spring, ball and valve

seat from the rear extension housing.


28/51

D04353

TF0959

SST

Q08385

Q08481

SST

TR-42


1930Author: Date:


6. REMOVE OIL PUMP PLATE

Remove the 3 bolts and oil pump plate.

7. REMOVE SPEED SENSOR DRIVE GEAR


(b) Remove the speed sensor drive gear.

8. REMOVE REAR OUTPUT SHAFT


(b) Using SST and a hammer, remove the rear output shaft.

SST 09325-12010

(c) Remove the 2 seal rings from the rear output shaft.

9. REMOVE DUST DEFLECTOR(a) Using a screwdriver and hammer, remove the rear exten-

sion housing dust deflector.

(b) Using a screwdriver and hammer, remove the rear output

shaft dust deflector.

10. REMOVE OIL SEAL

Using a screwdriver, pry out the oil seal from the rear extension

housing.

11. REMOVE BALL BEARING

(a) Using a screwdriver, remove the snap ring.

(b) Using SST and a press, remove the ball bearing from the

rear extension housing.

SST 09316-6001 1 (09316-00011, 09316-00021)


29/51

TR06R-02

Q02615

Q02616

Q02617


TR-43

1931Author: Date:


INSPECTION1. INSPECT DRIVEN ROTOR BODY CLEARANCE

(a) Install the drive rotor and driven rotor to the rear extension

housing.

(b) Using a feeler gauge, measure the body clearance be-

tween the drive rotor and extension housing.

Standard clearance:

0.08 - 0.17 mm (0.0031 - 0.0067 in.)

Maximum clearance:

0.17 mm (0.0067 in.)

If the body clearance exceeds the maximum, replace the drive

rotor and driven rotor.

2. INSPECT DRIVEN ROTOR TIP CLEARANCE

Using a feeler gauge, measure the tip clearance between the

drive rotor and driven rotor.

Standard clearance:

0.05 - 0.15 mm (0.0020 - 0.0059 in.)

Maximum clearance:

0.15 mm (0.0059 in.)

If the tip clearance exceeds the maximum, replace the drive ro-

tor and driven rotor.

3. INSPECT OIL PUMP SIDE CLEARANCE

Using a steel straight edge and feeler gauge, measure the side

clearance of oil pump.

Standard clearance:

0.03 - 0.10 mm (0.0012 - 0.0039 in.)

Maximum clearance:

0.10 mm (0.0039 in.)If the side clearance exceeds the maximum, replace the drive

rotor and driven rotor.


30/51

TR06S-02

TF0964

SST

TF0962

Q08482

SST

TF0967

SST

Q08482

SST


1932Author: Date:


REASSEMBLYHINT:


reassembly.

1. INSTALL BALL BEARING

(a) Using SST and a press, install the ball bearing.

SST 09316-6001 1 (09316-00011, 09316-00031)



A 1.70 (0.0669)

B 1.80 (0.0709)

(c) Using a screwdriver, install a new snap ring.

2. INSTALL DUST DEFLECTOR

(a) Using SST and a hammer, install a new rear extension

housing dust deflector.

SST 09316-6001 1 (09316-00011, 09316-00041)

(b) Using SST and a press, install a new rear output shaft

dust deflector.

SST 09316-2001 1, 09316-60011 (09316-00011)

3. INSTALL OIL SEAL

(a) Apply MP grease to the lip of a new oil seal.

(b) Using SST and a hammer, drive in the oil seal.

SST 09316-6001 1 (09316-00011, 09316-00031)


31/51

TF0969

SST

TF0958

D04353


TR-45

1933Author: Date:


4. INSTALL REAR OUTPUT SHAFT

(a) Using SST and a press, install the rear output shaft.

SST 09316- 20011, 09316- 60011 (09316- 00011,

09316-00031)

(b) Install the 2 seal rings to the rear output shaft.

(c) Select a snap ring that will allow the minimum axial play.


1 1.95 (0.0768)

2 2.05 (0.0807)

3 2.15 (0.0847)

4 2.25 (0.0886)

(d) Using a snap ring expander, install a new snap ring.

5. INSTALL SPEED SENSOR DRIVE GEAR

(a) Install the speed sensor drive gear.

(b) Using a snap ring expander, install the snap ring.

6. INSTALL OIL PUMP PLATE

(a) Install the oil pump plate.

(b) Install and torque the 3 bolts.

Torque: 4.9 Nm (50 kgfcm, 43 in.lbf)


32/51

Q08384

TF0977

Q00529


1934Author: Date:


7. INSTALL VALVE SEAT, BALL, SPRING AND SCREW

PLUG

(a) Apply gear oil to the ball.

(b) Install the valve seat, ball and spring.

(c) Apply liquid sealer to the screw plug threads.

Sealant:Part No. 08833-00080, THREE BOND 1344, LOCTITE

242 or equivalent

(d) Using a hexagon wrench, install and torque the screw

plug.


8. INSTALL DRIVEN ROTOR

(a) Apply gear oil to the driven rotor.

(b) Install the driven rotor.

9. INSTALL DRIVE ROTOR

(a) Apply gear oil to the drive rotor.

(b) Install the drive rotor.

HINT:

Align the alignment marks.

10. INSTALL OIL PUMP COVER

(a) Install the oil pump cover.

(b) Using a torx socket wrench (T30), install and torque the

3 screws.


NOTICE:

Align the oil hole of the rear extension housing and oilgroove end of the oil pump cover.

11. INSTALL OIL PUMP DRIVE SHAFT


33/51

TR069-02

D02653

GasketRear ExtensionHousing

Vehicle Speed SensorDriven Gear

Oil Strainer Case Cover

Transfer Indicator Switch

(Neutral Switch)Transfer Indicator Switch(Low Switch)

37 (380, 27)

37 (380, 27)

37 (380, 27)

x9

S 37 (380, 27)

S 37 (380, 27)

x5

Adjusting ShimRear Case

Snap Ring

Center DifferentialAssembly

x8

Bearing Race

Shift Fork No. 1

Idler Gear Assembly

Bearing Race

Shift Fork No. 1 Shaft

Bearing Race

Bearing Race

Input Shaft AssemblyLever Lock Pin

Washer

Oil Seal

Shift Inner Lever

Oil Receiver

Motor Actuator

Shift Outer Lever

11 (115, 8)

4.9 (50, 43 in.lbf)

S 19 (190, 14)18 (185, 13)

12 (120, 9)

12 (120, 9)

37 (380, 27)

37 (380, 27)

x6

Transfer Indicator Switch(Center Diff. Lock)

Shift Fork No. 2

Shift Fork No. 2 Shaft

Output Gear

Snap Ring

Front CaseBreather Hose

Clutch Sleeve

Front Extension Housing

Oil Seal


Non-reusable partS

Precoated part

Spring

Ball

Screw Plug

Gasket

Slotted Spring Pin

Washer

-TRANSFER TRANSFER ASSEMBLY

TR-7

1895Author: Date:


TRANSFER ASSEMBLY

COMPONENTS


34/51

TR06X-02

D02690

D02862

Q07105

D02860

TR-8


1896Author: Date:


DISASSEMBLY1. REMOVE BREATHER HOSE

2. REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR

Remove the bolt and driven gear.

3. REMOVE MOTOR ACTUATOR

Remove the 4 bolts and motor actuator.

4. REMOVE OUTPUT GEAR FROM FRONT CASE

5. REMOVE SCREW PLUG, SPRING AND BALL

(a) Using a torx socket wrench (T40), remove the screw plug.

(b) Using a magnetic finger, remove the spring and ball.

6. REMOVE TRANSFER INDICATOR SWITCH

Remove the 3 transfer indicator switches and 3 gaskets.

7. REMOVE FRONT EXTENSION HOUSING

Remove the 6 bolts and front extension housing.

HINT:

If necessary, tap the front extension housing lightly with a plas-

tic hammer.


35/51

Q00541

Front

Q02950

D02861

D02667

D02863


TR-9

1897Author: Date:


8. REMOVE CLUTCH SLEEVE WITH SHIFT FORK NO. 2

SHAFT AND SHIFT FORK NO. 2

9. SEPARATE SHIFT FORK NO. 2 SHAFT AND SHIFT

FORK NO. 2

(a) Using 2 screwdrivers and a hammer, tap out the 3 snap

rings from the shift fork No. 2 shaft.

(b) Separate the shift fork No. 2 shaft and shift fork No. 2.

10. REMOVE REAR EXTENSION HOUSING

Remove the 9 bolts and rear extension housing.

HINT:

If necessary, tap the rear extension housing lightly with a plastic

hammer.

11. REMOVE ADJUSTING SHIMS

12. REMOVE OIL STRAINER FROM REAR CASE

Remove the 2 bolts and oil strainer.

13. REMOVE CASE COVER

(a) Remove the 5 bolts.


36/51

D02668

D02669

D02864

TF0854

D02670

TR-10


1898Author: Date:


(b) Using a brass bar and hammer, tap the case cover and

remove it.

14. SEPARATE FRONT CASE AND REAR CASE

(a) Using a snap ring expander, remove the snap ring from

the rear case.

(b) Remove the 8 bolts.

(c) Using a brass bar and hammer, tap the rear case and sep-

arate it.

15. REMOVE 2 BEARING RACES FROM REAR CASE

16. REMOVE INPUT SHAFT ASSEMBLY

Using a plastic hammer, remove the input shaft assembly from

the front case.


37/51

TF0986

TF0857

D04308

Socket Wrench

D02671

TF0862

SST


TR-11

1899Author: Date:


17. REMOVE IDLER GEAR ASSEMBLY WITH CENTER

DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND

SHIFT FORK NO. 1 SHAFT FROM FRONT CASE

18. SEPARATE SHIFT FORK NO. 1 AND SHIFT FORK NO.

1 SHAFT

(a) Using a pin punch and hammer, drive out the slotted

spring pin.

(b) Separate the shift fork No. 1 and shift fork No. 1 shaft.

19. REMOVE SHIFT OUTER LEVER AND INNER LEVER

(a) Remove the nut and washer from the shift outer lever.

(b) Using a brass bar, hammer and socket wrench, tap out

the lever lock pin.

(c) Remove the shift outer lever, washer and inner lever from

the front case.

20. IF NECESSARY, REPLACE INNER SHIFT LEVER OIL

SEAL

(a) Using a screwdriver, pry out the oil seal from the front

case.

(b) Apply MP grease to the lip of a new oil seal.

(c) Using SST and a hammer, drive in a new oil seal.

SST 09950- 60010 (09951- 00270), 09950- 70010

(09951-07150)


38/51

TF0864

SST

SST

D02672

D02770

SST

TF0867

TR-12


1900Author: Date:


21. IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL

(a) Using SST and a hammer, drive out the oil seal.

SST 09316-6001 1 (09316-00011)

(b) Apply MP grease to the lip of a new oil seal.

(c) Using SST and a hammer, drive in a new oil seal.

SST 09316-6001 1 (09316-00011, 09316-00031)

22. REMOVE OIL RECEIVER FROM FRONT CASE

Remove the bolt and oil receiver.

23. REMOVE 2 BEARING RACES FROM FRONT CASE

(a) Using SST, remove the bearing race (for the idler gear).

SST 09950- 40011 (09951- 04020, 09952- 04010,

09953- 04030, 09954- 04010, 09955- 04061,

09957-04010), 09950-60010 (09951-00320)

(b) Using a brass bar and hammer, remove the bearing race

(for the output shaft).


39/51

TR06Y-01

D02673

D02662

SST

D02661

SST

D02672

D04309Socket Wrench


TR-13

1901Author: Date:


REASSEMBLY1. INSPECT SHIFT FORK NO. 2 AND CLUTCH SLEEVE

CLEARANCE

Using a feeler gauge, measure the clearance between the shift

fork No. 2 and clutch sleeve.

Standard clearance:

0.10 - 0.40 mm (0.0039 - 0.0157 in.)

Maximum clearance:

0.40 mm (0.0157 in.)

2. INSTALL THE BEARING RACE (FOR THE OUTPUT

SHAFT)

Using SST and a press, install the bearing race.

SST 09316-6001 1 (09316-00011, 09316-00031),

09950-60020 (09951-00890)

3. INSTALL THE BEARING RACE (FOR THE IDLER

GEAR)

Using SST and a press, install the bearing race.

SST 09316-6001 1 (09316-00011, 09316-00031),

09950-60020 (09951-00790)

4. INSTALL OIL RECEIVER TO FRONT CASE

Install the oil receiver and bolt.


5. INSTALL SHIFT OUTER LEVER AND INNER LEVER

(a) Install the shift inner lever, washer and outer lever to the

front case.

(b) Using a pin punch, hammer and socket wrench, tap in the

lever lock pin.

(c) Install the washer and nut to the shift outer lever.



40/51

TF0857

TF0986

D02756

FIPG3 mm (0.12 in.)

D02864A

D02669

TR-14-TRANSFER TRANSFER ASSEMBLY

1902Author: Date:


6. ASSEMBLE SHIFT FORK NO. 1 AND SHIFT FORK NO.

1 SHAFT

(a) Assemble the shift fork No. 1 and shift fork No. 1 shaft.

(b) Using a pin punch and hammer, drive in the slotted spring

pin.

7. INSTALL IDLER GEAR ASSEMBLY WITH CENTER

DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND

SHIFT FORK NO. 1 SHAFT TO FRONT CASE

NOTICE:

Set the shift inner lever into the fork head part of the shift

fork No. 1 securely.8. INSTALL INPUT SHAFT ASSEMBLY

9. INSTALL 2 BEARING RACES TO REAR CASE

10. ASSEMBLY FRONT CASE AND REAR CASE

(a) Apply FIPG to the front case.

FIPG:

Part No. 08826-00090, THREE BOND 1281 or

equivalent

(b) Assemble the front case and rear case.

(c) Apply liquid sealer to the A bolt threads.

Sealant:

Part No. 08833-00080, THREE BOND 1344, LOCTITE

242 or equivalent

(d) Install the 8 bolts.


11. ASSEMBLE FRONT CASE AND REAR CASE

Using a snap ring expander, install the snap ring to the rear

case.


41/51

D02754

FIPG

5 mm (0.20 in.)

D02863

D02667

Z18975

A

Z18976

B


TR-15

1903Author: Date:


12. INSTALL CASE COVER

(a) Apply FIPG to the rear case.

FIPG:


equivalent

(b) Install the case cover.

(c) Apply liquid sealer to the bolt threads.

Sealant:


242 or equivalent

(d) Install the 5 bolts.


13. INSTALL OIL STRAINER TO REAR CASE

Install the oil strainer and 2 bolts.


14. SELECT ADJUSTING SHIM FOR IDLER GEAR REAR

TAPER ROLLER BEARING

(a) Using vernier calipers, measure dimension A.

(b) Lightly hole down the bearing outer race in the thrust

direction to eliminate any looseness before making the

measurement.

(c) Using a steel straight edge and feeler gauge, measure

the clearance of dimension B.

(d) Calculate the required thickness of the adjusting shim.

Thickness: Dimension A + Dimension B + [0.022

- 0.049 mm, (0.0009 - 0.0019 in.)]


42/51

TF1063

C

TF1064

F E

D

TF1065

F

G H


1904Author: Date:


(e) From the following table, select a shim so that its thick-

ness is within the range of the calculation.


2 0.30 (0.0118) 8 3.20 (0.1260)

3 0.45 (0.0177) 9 3.40 (0.1339)

4 2.40 (0.0945) 10 3.60 (0.1417)

5 2.60 (0.1024) 11 3.80 (0.1496)

6 2.80 (0.1102) 12 4.00 (0.1575)

7 3.00 (0.1181) 13 0.55 (0.0216)

15. SELECT ADJUSTING SHIM FOR OUTPUT SHAFT TA-

PER ROLLER BEARING

(a) Using a steel straight edge and feeler gauge, measure

the clearance of dimension C.

(b) Lightly hold down the bearing outer race in the thrust

direction to eliminate any looseness before making themeasurement.

(c) Using a steel straight edge and vernier calipers with depth

gauge, measure dimension D.

(d) Dimension D is the straight edge thickness (Dimension

F) subtracted from dimension E in the illustration to the

left.

Dimension D: Dimension E - Dimension F

(e) Using a steel straight edge and vernier calipers with depth

gauge, measure dimension G.

(f) Dimension G is the straight edge thickness (Dimension

F) subtracted from Dimension H.

Dimension G: Dimension H - Dimension F

(g) Calculate the required thickness of the adjusting shim.

Thickness: Dimension G - (Dimension D - Di-mension C) + [0.014 0.039 mm, (0.0006 0.0015

in.)]

(h) From the following table, select a shim so that its thick-

ness is within the range of the calculation.


B 0.30 (0.0118) H 1.80 (0.0709)

C 0.45 (0.0177) J 2.00 (0.0787)

D 1.00 (0.0394) K 2.20 (0.0866)

E 1.20 (0.0472) L 2.40 (0.0945)

F 1.40 (0.0551) M 2.60 (0.1024)

G 1.60 (0.0630) N 0.55 (0.0216)


43/51

D01995

FIPG

3 mm (0.12 in.)

D02861

Q00541

Front

D01991

FIPG

4 mm (0.16 in.)

D02860


TR-17

1905Author: Date:


16. INSTALL REAR EXTENSION HOUSING

(a) Apply FIPG to the rear extension housing.

FIPG:


equivalent

(b) Install the rear extension housing and 9 bolts.


17. ASSEMBLE SHIFT FORK NO. 2 SHAFT AND SHIFT

FORK NO. 2

(a) Install the shift fork No. 2 to the shift fork No. 2 shaft.

(b) Install the 3 snap rings to the shift fork No. 2 shaft.

18. INSTALL CLUTCH SLEEVE WITH SHIFT FORK NO. 2

SHAFT AND SHIFT FORK NO. 2

HINT:

Make sure to install the clutch sleeve in the correct direction.

19. INSTALL FRONT EXTENSION HOUSING

(a) Apply FIPG to the front extension housing.

FIPG:


equivalent

(b) Install the front extension housing and 6 bolts.


HINT:

Set the clutch sleeve in differential lock condition.

20. INSTALL TRANSFER INDICATOR SWITCH

Install the 3 transfer indicator switches with 3 new gaskets.



44/51

Q07105

D02862

D02666FIPG

4 mm (0.16 in.)

Q04610

D02690


1906Author: Date:


21. INSTALL BALL, SPRING AND SCREW

(a) Install the ball and spring.

(b) Apply liquid sealer to the screw plug threads.

Sealant:


242 or equivalent(c) Using a torx socket wrench (T40), install the screw plug.


22. INSTALL OUTPUT GEAR TO FRONT CASE

HINT:

Apply gear oil to the output gear.

NOTICE:

Do not turn the output gear.

23. INSTALL MOTOR ACTUATOR

(a) Apply FIPG to the motor actuator.

FIPG:


equivalent

HINT:

Set the motor actuator in differential lock condition.

(b) Install the motor actuator and 4 bolts.


24. INSTALL SPEED SENSOR DRIVE GEAR

Install the driven gear and bolt.


25. INSTALL BREATHER HOSE


45/51

TR064-02

-TRANSFER TRANSFER SYSTEM

TR-1

1889Author: Date:


TRANSFER SYSTEM

PRECAUTIONWhen working with FIPG material, you must observe the following.

S Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-

faces.S Thoroughly clean all components to remove all the loose material.

S Clean both sealing surfaces with a non-residue solvent.

S Apply FIPG in an approx. 1.2 mm (0.047 in.) wide bead along the sealing surface.

S Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must

be removed and reapplied.


46/51

TR066-02

D02887

Transfer Indicator SwitchConnector(Neutral Switch)

Transfer IndicatorSwitch Connector(Center Diff. Lock)

Transfer Indicator Switch Connector

(Low Switch)

Motor Actuator Connector

No. 1 Vehicle Speed Sensor Connector

Rear Propeller Shaft

Breather Hose

Transfer

Ground Cable

106 (1,080, 78)

69 (700, 51)

69 (700, 51)

Clip

Plate WasherWave Washer

Transfer Shift Lever RodAssembly

Bushing

69 (700, 51)

69 (700, 51)

Transfer Case Protector

: Specified torqueNm (kgfcm, ftlbf)

Front Propeller Shaft

Crossmember

50 (510, 37)

50 (510, 37)

74 (750, 54)

50 (510, 37)

28 (290, 21)

106 (1,080, 78)

106 (1,080, 78)

106 (1,080, 78)

80 (820, 59)

80 (820, 59)

80 (820, 59)

80 (820, 59)

-TRANSFER TRANSFER UNIT

TR-3

1891Author: Date:


TRANSFER UNIT

COMPONENTS


47/51

TR068-02

TR-6-TRANSFER TRANSFER UNIT

1894Author: Date:


INSTALLATIONInstallation is in the reverse order of removal (See page TR-4 ).

HINT:

S Apply MP grease to the transfer adaptor oil seal.

S After install, do the road test.
http://../04rmsour/2004/04cruise/tr/trauni/remo.pdfhttp://../04rmsour/2004/04cruise/tr/trauni/remo.pdf


48/51

TR067-02

D02645

D02646

Oil Level0 - 5 mm

Filler Plug Drain Plug

D01618

Q09803

Wooden Block

TR-4-TRANSFER TRANSFER UNIT

1892Author: Date:


REMOVAL1. RAISE VEHICLE

NOTICE:

Make sure that the vehicle is securely supported.

2. REMOVE TRANSFER CASE PROTECTOR

Remove the 3 bolts and transfer case protector.


3. DRAIN TRANSFER OIL

Oil grade: API GL-4 or GL-5

Viscosity: SAE 75 W-90

Capacity: 1.3 liters (1.4 US qts, 1.1 lmp. qts)


4. REMOVE FRONT AND REAR PROPELLER SHAFTS

(See page PR-4 )

5. DISCONNECT TRANSFER SHIFT LEVER ROD AS-

SEMBLY

Remove the clip, plate washer, wave washer and bushing, and

disconnect the transfer shift lever rod assembly.

6. DISCONNECT GROUND CABLE

Remove the bolt and disconnect the ground cable from the

transfer.

7. REMOVE CROSSMEMBER

(a) Support the transmission, as shown.

NOTICE:

Use a wooden block so not to damage the transmission oil

pan.

(b) Remove the 8 bolts, 2 nuts and crossmember.

Torque:Bolt: 50 Nm (510 kgfcm, 37 ftlbf)

Nut: 74 Nm (750 kgfcm, 54 ftlbf)
http://../04rmsour/2004/04cruise/pr/psa1/remo.pdfhttp://../04rmsour/2004/04cruise/pr/psa1/remo.pdf


49/51

Q09804

5 mm (0.20 in.)or More

HoseClip

Pipe

D02643

-TRANSFER TRANSFER UNIT

TR-5

1893Author: Date:


8. DISCONNECT BREATHER HOSE

HINT:

At the time of installation, assemble the clip to the position

shown in the illustration.

9. DISCONNECT NO. 1 VEHICLE SPEED SENSOR, 3

TRANSFER INDICATOR SWITCH AND MOTOR AC-TUATOR CONNECTORS

10. JACK UP TRANSFER SLIGHTLY

Using a transmission jack, support the transfer.

11. REMOVE TRANSFER FROM TRANSMISSION

(a) Disconnect the wire harness from the transfer.

(b) Remove the 6 transfer adaptor rear mounting bolts.


(c) Pull out the transfer down and toward the rear.


50/51

TR065-02

TR-2

-TRANSFER TROUBLESHOOTING

1890Author: Date:


TROUBLESHOOTING

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely

cause of the problem. Check each part in order. If necessary, replace these parts.

Symptom Suspect Area See page

Noise

6. Oil (Level low)

7. Oil (Wrong)

8. Transfer faulty

TR-4

TR-4

TR-7

Oil leakage

1. Oil (Level too high)

2. Gasket (Damaged)

3. Oil seal (Worn or damaged)

4. O-ring (Worn or damaged)

TR-4

TR-7

TR-7

-

Transfer corner braking Center differential or transfer faulty TR-7
http://../04rmsour/2004/04cruise/tr/trauni/remo.pdfhttp://../04rmsour/2004/04cruise/tr/trauni/remo.pdfhttp://../04rmsour/2004/04cruise/tr/traass/comp.pdfhttp://../04rmsour/2004/04cruise/tr/trauni/remo.pdfhttp://../04rmsour/2004/04cruise/tr/traass/comp.pdfhttp://../04rmsour/2004/04cruise/tr/traass/comp.pdfhttp://../04rmsour/2004/04cruise/tr/traass/comp.pdfhttp://../04rmsour/2004/04cruise/tr/traass/comp.pdfhttp://../04rmsour/2004/04cruise/tr/traass/comp.pdfhttp://../04rmsour/2004/04cruise/tr/traass/comp.pdfhttp://../04rmsour/2004/04cruise/tr/trauni/remo.pdfhttp://../04rmsour/2004/04cruise/tr/traass/comp.pdfhttp://../04rmsour/2004/04cruise/tr/trauni/remo.pdfhttp://../04rmsour/2004/04cruise/tr/trauni/remo.pdf


51/51

TR06Z-02

Transfer Shift Lever Assembly

Transfer Shift Lever RodAssembly

Plate Washer

Clip

Wave Washer

Bushing

Bushing

S Gasket

Snap Ring

Wave WasherPlate Washer

Transfer Shift LeverBoot

Wiring Harness Clamp Bracket

Transfer Shift Lever Boot

Transfer Control Shift Lever Retainer

S Gasket

19 (190, 14)

14 (140, 10)


-TRANSFER TRANSFER SHIFT LEVER ASSEMBLY

TR-47

TRANSFER SHIFT LEVER ASSEMBLY

COMPONENTS

Transfer.pdf

Documents

Transcript of Transfer.pdf