Disassembly (Transfer Case)
WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 1994 Toyota MR2, 1993 Toyota MR2, 1993 Toyota Celica, 1992 Toyota MR2, and 1992 Toyota Corolla. However, it is still accessible from the selected car via links, so may be relevant.
- Remove mode select lever and rod.
- Remove dust deflector from extension housing. Remove 4 bolts. Remove "O" ring from housing. Using Seal Puller (09308-00010), remove extension housing oil seal.
- Remove 5 bolts from transfer right case retainer. Using plastic hammer, remove right case retainer. Remove "O" ring and apply gasket from retainer. Remove transfer inspection hole cover.
- Using Lock Nut Wrench (09326-20011) and spring tension gauge, measure driven pinion preload and backlash between driven pinion and ring gear. Driven pinion preload at starting point is 2.0-3.1 lbs. (.9-1.4 kg). Using lock nut wrench and spring gauge, measure total preload. Total preload at starting point is 1.1-2.0 lbs. (.5-.9 kg). Add driven pinion preload.
- Using dial indicator, measure ring gear backlash. Backlash should be between .0051-.0071" (.130-.180 mm).
- Remove driven pinion bearing cage. Remove "O" ring and shim from bearing cage. Remove transfer right case. Remove center differential assembly. Remove apply gasket from left case.
- Remove oil pump driven gear and strainer. Remove "O" ring from oil pump strainer. Remove adjusting nut lock plate. Remove "O" ring from bolt.
- Using Adjusting Nut Wrench (09318-12010), remove adjusting nut and oil reserver from right case. Remove outer race with a brass bar and hammer. Using Oil Seal Puller (09308-00010), remove outer race and plate washer. Remove oil seal.