Diesel Data: Automotive Repair
Home >> Toyota >> 1990 >> Corolla Wagon 4WD L4-96.8 1587cc 1.6L DOHC (4A-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Disassembly and Assembly >> Component Parts Overhaul >> Transfer Assembly (A241H) >> Transfer (A241H)

Transfer (A241H)




COMPONENTS

REMOVAL OF COMPONENTS PARTS




1. REMOVE TRANSFER MODE SELECT LEVER AND ROD

2. REMOVE EXTENSION HOUSING




a. Remove four bolts and extension housing.
b. Remove the O-ring from the extension housing.




c. Using a screwdriver, remove the oil seal.

3. REMOVE TRANSFER RIGHT CASE RETAINER




a. Remove the five bolts.
b. Using a plastic hammer, remove the right case retainer.




c. Remove the O-ring and apply gasket from the right case retainer.




4. REMOVE TRANSFER INSPECTION HOLE COVER
Remove the three bolts and inspection hole cover.

5. CHECK PRELOAD




a. Using SST and a spring tension gauge, measure the driven pinion preload of the backlash between the driven pinion and ring gear.

SST 09326-20011

Driven pinion preload (at starting): 0.9 - 1.4 kg (2.0 - 3.1 lb, 8.8 - 13.7 N)




b. Using SST and a spring tension gauge, measure the total preload.

SST 09326-20011

Total preload (at starting):
Add driven pinion preload 0.5 - 0.9 kg (1.1 - 2.0 lb, 4.9 - 8.8 N)

6. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)

7. CHECK TOOTH CONTACT




8. REMOVE DRIVEN PINION BEARING CAGE
a. Remove the six bolts.
b. Using a plastic hammer, remove the bearing cage.
c. Remove the O-ring and the shims from the bearing cage.




9. REMOVE TRANSFER RIGHT CASE
Remove the ten bolts and right case.




10. REMOVE CENTER DIFFERENTIAL ASSEMBLY




11. REMOVE APPLY GASKET
Remove the apply gasket from the left case.




12. REMOVE OIL PUMP STRAINER AND OIL PUMP DRIVEN GEAR




13. REMOVE ADJUSTING NUT LOCK PLATE
a. Remove the bolt and nut lock plate from the right case.
b. Remove the O-ring from the bolt.

14. REMOVE DIFFERENTIAL RIGHT SIDE BEARING OUTER RACE




a. Using SST, remove the adjusting nut and an oil reserver from the right case.

SST 09318-12010




b. Using a brass bar, remove the outer race.




15. REMOVE DIFFERENTIAL LEFT SIDE BEARING OUTER RACE
Using SST, remove the outer race and washer.

SST 09308-00010




16. REMOVE LEFT CASE OIL SEAL
Using SST, remove the oil seal.

SST 09308-00010


ASSEMBLY OF COMPONENT PARTS

1. INSTALL LEFT CASE SIDE




a. Install the plate washer.




b. Using SST and a press, press in the outer race.

SST 09316-60010 (09316-00010, 09316-00060)

2. INSTALL RIGHT CASE SIDE




a. Using SST and a press, press in outer race as shown.

SST 09316-60010 (09316-00010, 09316-00060)




b. Install the bearing adjusting nut and oil reserver, until it touch the outer race.

3. ADJUST RING GEAR BACKLASH




a. Install the shim to the driven pinion bearing cage assembly.

HINT: First install a shim of the some thickness as before.




b. Install driven pinion bearing cage.

Torque: 400 kg-cm (29 ft-lb, 39 N.m)

HINT: Do not install the O-ring.




c. Install ring gear mounting case and center differential case.
d. Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)







e. Referring to the table bellow, select the plate washer which will ensure that the backlash is with in specification.

Try select a washer of the same size.

4. ADJUST TOTAL PRELOAD




a. Install the transfer right case.

HINT: Do not apply seal packing and do not install gasket.

Torque: 450 kg-cm (33 ft-lb, 44 N.m)




b. Using SST and a spring tension gage, measure the total preload.

SST 09326-20011

Preload (at starting):
New bearing
Add driven pinion preload 1.3 - 1.4 kg (2.9 - 3.11 lb, 12.7 - 13.7 N.m)
Reused bearing
Add driven pinion preload 0.5 - 0.9 kg (1.1 - 2.0 lb, 4.9 - 8.8 N.m)




c. Adjust the total preload by tightening the adjusting nut with SST.

SST 09318-12010

HINT: Measure the preload while tightening the bearing adjusting nut a little at a time.




5. CHECK RING GEAR BACKLASH
a. Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 - 0.18 mm( 0.0051 - 0.0071 in.)

b. When the backlash is outside the standard value, select a different plate washer to the one selected step 3. Again adjust the backlash and total preload.




6. CHECK TOOTH CONTACT
a. Coat 3 or 4 teeth at four different position on the ring gear with red lead.
b. Rotate the ring gear, inspect the teeth pattern.







c. If the teeth are not connecting properly, again the proper shim and plate.




7. REMOVE TRANSFER RIGHT CASE
Remove the ten bolts and transfer right case.




8. REMOVE RING GEAR MOUNTING CASE AND CENTER DIFFERENTIAL CASE




9. REMOVE DRIVEN PINION BEARING CAGE




10. REMOVE LEFT CASE BEARING OUTER RACE AND PLATE WASHER




11. INSTALL OIL SEAL
a. Using SST, install a new oil seal as shown.

SST 09316-60010 (09316-00010, 09316-00030)

Oil seal depth: 3 mm (0.12 in.)

b. Coat the lip of oil seal with MP grease.

12. INSTALL LEFT CASE BEARING OUTER RACE




a. Install the plate washer. (previously selected)




b. Using SST and a press, press in the outer race.

SST 09316-60010 (09316-00010, 09316-00060)




13. INSTALL DRIVEN PINION BEARING CAGE
a. Coat the O-ring with gear oil, and install it to the bearing cage.
b. Install shim (previously selected) and bearing cage assembly.

Torque: 400 kg-cm (29 ft-lb, 39 N.m)




14. INSTALL RING GEAR MOUNTING CASE AND CENTER DIFFERENTIAL CASE

15. INSTALL TRANSFER RIGHT CASE




a. Install a new apply gasket to the left case.




b. Install oil pump strainer and driven gear to the right case.




c. Apply seal packing to the left case as shown in the image.

Seal packing: Part No.08826-00090 THREE BOND 1281 or equivalent

HINT: Install the right case as soon as the seal packing is applied.




d. Install right case and ten bolts.

Torque: 450 kg-cm (33 ft-lb, 44 N.m)

16. CHECK TOTAL PRELOAD




17. INSTALL ADJUSTING NUT LOCK PLATE
Install the lock plate so that the projection from the lock plate fits properly into the groove of the adjusting nut.

18. INSTALL TRANSFER INSPECTION HOLE COVER




a. Apply seal packing to the left case as shown in the image.

Seal packing: Parts No.08826-00090 THREE BOND 1281 or equivalent

HINT: Install the cover as soon as the seal packing is applied.




b. Install hole cover.

Torque: 170 kg-cm (12 ft-lb, 17 N.m)

19. INSTALL TRANSFER RIGHT CASE RETAINER




a. Coat a O-ring with gear oil, and install it and new apply gasket.




b. Install case retainer.

Torque: 260 kg-cm (19 ft-lb, 25 N.m)

20. INSTALL EXTENSION HOUSING




a. Using SST and a hammer, drive in a new oil seal as shown.

SST 09325-20010

Oil seal depth: 0.1 - 0.9 mm (0.004 - 0.035 in.)

b. Coat the lip of the oil seal with MP grease.




c. Coat a new O-ring with gear oil.
d. Install dust deflector and O-ring to the extension housing.
e. Install extension housing to the driven pinion bearing cage.

Torque: 260 kg-cm (19 ft-lb, 25 N.m)




21. INSTALL TRANSFER MODE SELECT LEVER AND ROD
a. Install the lever, rod and lever guide.

Torque: 130 kg-cm (9 ft-lb, 13 N.m)

b. Install the bolt while setting the lever as shown.

Torque: 130 kg-cm (9 ft-lb, 13 N.m)
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