Reassembly

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

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
NOTE: 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.
(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.

HINT: Using a torque wrench with a fulcrum length of 750 mm (29.53 in.).
NOTE: 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):

HINT:
- Use a torque wrench with a fulcrum length of 130 mm (5.12 in.).
- 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 driven pinion. Then perform the procedure again. If the tightening torque is less than the specified torque, replace the pinon bearing spacer with a new one and adjust it.
- Do not loosen the pinion 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, set the ring gear onto the transfer ring gear mounting case, and then temporarily tighten the 10 bolts.
Torque: 78 Nm (790 kgf-cm, 57 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.

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 LH outer race 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 a new 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 a new No. 2 transfer ring gear mounting case washer.
HINT: Install a new 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 the measure the backlash.
Backlash:
0.10 to 0.18 mm (0.00394 to 0.00709 in.)
NOTE: 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 and install it to meet the specified range.

13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.
(b) Rotate the ring gear to inspect the tooth contact pattern.

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

NOTE: 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):

HINT:
- Use a torque wrench with a fulcrum length of 130 mm (5.12 in.).
- Turn the driven pinion counterclockwise and clockwise several times.
If the preload is outside the specified range, replace the No. 2 transfer ring gear mounting case washer with one that is thicker or thinner as necessary and recheck.

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:
33.7 to 34.3 mm (1.327 to 1.350 in.)
NOTE: Do not install the oil seal at an angle.

(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 in the illustration.
SST: 09316-60011
09316-00011
Drive in depth:
9.7 to 10.3 mm (0.382 to 0.406 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 in the illustration.
SST: 09950-60010
09951-00350
09951-00570
09952-06010
SST: 09950-70010
09951-07150
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 surface 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)
NOTE: Assemble transfer extension housing sub-assembly within 10 minutes after the 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 positions shown in the illustration.

22. INSTALL TRANSFER DYNAMIC DAMPER

(a) Install the transfer dynamic damper with the 3 bolts to the transfer extension housing sub-assembly.
Torque: 26 Nm (260 kgf-cm, 19 ft-lbf)
23. INSTALL TRANSFER CASE BREATHER PLUG

(a) Using SST and a hammer, tap in a new breather plug.
SST: 09612-10093
09612-10061
24. INSTALL BREATHER OIL DEFLECTOR

(a) Install the breather oil deflector with the bolt.
Torque: 6.5 Nm (66 kgf-cm, 58 in-lbf)
25. INSTALL NO. 1 TRANSFER CASE COVER

(a) Remove any FIPG material and be careful not to drop oil on the contact surfaces of the No. 1 transfer case cover and the transfer case.
(b) Degrease the surface with a non-residue solvent.
(c) Apply FIPG to the No. 1 transfer case cover.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(d) Install the No. 1 transfer case cover with the 8 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft-lbf)

NOTICE:
- Wait for at least one hour after installing the No. 1 transfer case cover before adding transfer oil.
- Assemble the No. 1 transfer case cover within 10 minutes after the FIPG application.

26. 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)
27. 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)
28. 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)
29. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT
(a) Install the 4 transfer and transaxle setting stud bolts to the transfer case positions shown in the illustration.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
HINT: Install the shorter end of the stud bolts to the transfer.

Stud bolt length:
a
30 mm (1.1811 in.)
b
12 mm (0.4724 in.)
c
22 mm (0.8661 in.)