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Home >> Toyota >> 1993 >> Paseo Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 61 (Overhaul - A-241E/H/L & A-243E) >> Component Disassembly & Reassembly >> Transfer Case (A-241H) >> Reassembly (Transfer Case)

Reassembly (Transfer Case)

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  1. Install case side plate washer. Using Bearing Replacer (09316-60010) and an arbor press, install case side outer race. Using bearing replacer and an arbor press, install right case side outer race. Install bearing adjusting nut and oil reserver until nut and reserver touch outer race. See Fig 1.
  2. Install shim(s) to driven pinion bearing cage assembly. Install same thickness shim(s) as removed. Install driven pinion bearing cage. Tighten to 29 ft. lbs. (39 N.m). DO NOT  install "O" ring. Install ring gear mounting case and center differential case. Using a dial indicator, measure ring gear backlash. Backlash should be .0051-.0071" (.130-.180 mm). See Fig 1. If backlash exceeds specification, install correct plate washer on ring gears. See RING GEAR PLATE WASHER SPECIFICATIONS  table.
    Fig 1: Measuring Ring Gear Backlash
    G93E25795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    RING GEAR PLATE WASHER SPECIFICATIONS

    ID Mark Thickness: In. (mm)
    71 .0839 (2.130)
    72 .0850 (2.160)
    73 .0862 (2.190)
    74 .0874 (2.220)
    75 .0886 (2.250)
    76 .0898 (2.280)
    77 .0909 (2.310)
    78 .0921 (2.340)
    79 .0933 (2.370)
    80 .0945 (2.400)
    81 .0957 (2.430)
    82 .0969 (2.460)
    83 .0980 (2.490)
    84 .0992 (2.520)
    85 .1004 (2.550)
    86 .1016 (2.580)
    87 .1028 (2.610)
    88 .1039 (2.640)
    89 .1051 (2.670)
    90 .1063 (2.700)
    91 .1075 (2.730)
    92 .1087 (2.760)
    93 .1098 (2.790)
    94 .1110 (2.820)
  3. Install transfer right case. DO NOT  apply seal packing and gasket. Tighten bolts to 32 ft. lbs. (44 N.m). Using Lock Nut Wrench (09326-20011) and spring tension gauge, measure total preload. Total preload at starting point is 1.1-2.0 lbs. (.5-.9 kg). Add drive pinion preload. Rotate drive pinion counterclockwise and clockwise several times. Using Adjusting Nut Wrench (09318-12010) and tighten wrench, adjust total preload by tightening bearing adjusting nut in small increments. Measure ring gear backlash. Backlash should be .0051-.0071" (.130-180 mm). If backlash exceeds specification, install correct plate washer on ring gear. See RING GEAR PLATE WASHER SPECIFICATIONS  table.
  4. Check ring gear tooth contact. Coat 3 or 4 teeth at 4 different positions on ring gear with Red lead. Rotate the ring gear, and inspect teeth pattern. See Fig 2. If the teeth are not meshing properly, install proper shim and plate washer. See RING GEAR SHIM SPECIFICATIONS  table and RING GEAR PLATE WASHER SPECIFICATIONS  tables.
    Fig 2: Checking Ring Gear Tooth Contact
    G93F25796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    RING GEAR SHIM SPECIFICATIONS

    ID Mark Thickness: In. (mm)
    A .0118 (.300)
    B .0130 (.330)
    C .0142 (.360)
    D .0154 (.390)
    E .0165 (.420)
    F .0177 (.450)
    G .0189 (.480)
    H .0201 (.510)
    J .0213 (.540)
    K .0224 (.570)
  5. Remove transfer right case. Remove ring gear mounting case and center differential case. Remove driven pinion bearing cage assembly. Using Oil Seal Puller (09308-00010), remove outer race and plate washer.
  6. Using Bearing Replacer (09316-60010), install new oil seal. Oil seal depth is .12" (3 mm). Coat lip of oil seal with grease. Install plate washer. Using Bearing Replacer (09316-60010) and an arbor press, install left case bearing outer race.
  7. Coat "O" ring with gear oil and install on driven pinion bearing cage assembly. Install driven pinion bearing cage with adjusting shim to transfer left case. Install 6 bolts. Tighten bolts to 29 ft. lbs. (39 N.m). Install ring gear mounting case and center differential case.
  8. Install new apply gasket to left case. Coat "O" ring with gear oil. Install "O" ring to oil pump strainer. Install strainer to transfer right case. Install bolts. Tighten to 48 INCH lbs. (5.4 N.m) Install oil pump driven gear. Apply Three Bond (1281) seal packing to left case. Install right case as soon as seal packing is applied. Install right case to left case. Install 10 bolts. Tighten to 32 ft. lbs. (44 N.m). Check total preload as shown in step  3.
  9. Install lock plate so that projection from lock plate fits properly into groove of adjusting nut. When lock plate cannot be installed, tighten adjusting nut smallest amount possible. Coat new "O" ring with gear oil. Install "O" ring on lock bolt. Install and tighten lock nut to 63 INCH lbs. (7 N.m).
  10. Apply seal packing Three Bond (1281) to left case. Install inspection hole cover as soon as seal packing is applied. Install hole cover to transfer left case. Install 3 bolts. Tighten to 12 ft. lbs. (16 N.m).
  11. Coat new "O" ring with gear oil. Install "O" ring and new apply gasket. Install right case retainer to transfer right case. Install 5 bolts. On A-241H, tighten bolts to 19 ft. lbs. (25 N.m).
  12. Use Oil Plug (09325-20010) and a hammer to install new oil seal in extension housing. Coat lip of oil seal with grease. Install new "O" ring in extension housing. Install extension housing to driven pinion bearing cage. Install 4 bolts. Tighten to 18 ft. lbs. (25 N.m). Using a hammer, install dust deflector. Install dynamic damper. Tighten to 18 ft. lbs. (25 N.m).
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