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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 (A-241H): Reassembly

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  1. On A-241H, apply ATF to NEW oil plug "O" ring. Install "O" ring on oil plug. Install oil strainer and plug. On both models, use Bearing Tool (09608-35014) to install front side bearing outer race to bearing cage. Using Bearing Replacer (09608-30022), install rear side bearing outer race. Using Bearing Replacer (09506-35010), install front side bearing. Install NEW spacer to driven pinion.
  2. Install bearing cage to driven pinion. Using bearing replacer, install rear side bearing to driven pinion.
  3. Adjust drive pinion preload. Using Lock Nut Wrench (09326-20011) and torque wrench, tighten nut to 72 ft. lbs. (98 N.m). Using lock nut wrench and spring tension gauge, measure preload. Rotate driven pinion counterclockwise and clockwise several times to allow bearings to settle. Measure preload of driven pinion at starting point. Preload with new bearing is 4.0-6.4 lbs. (1.8-2.9 kg). With old bearing, preload should be 2.0-3.1 lbs. (.9-1.4 kg).
  4. If preload exceeds specification, replace bearing spacer. If preload is less than specification, retighten nut 5-10 degrees at a time until specified preload is reached.
  5. If maximum torque is exceeded by retightening nut, replace bearing spacer. Repeat preload procedure. DO NOT  back off pinion nut to reduce preload. Maximum nut torque is 174 ft. lbs. (235 N.m). Stake lock nut.


  1. Using Bearing Replacer (09226-10010) and an arbor press, install holder bearing. Install snap ring.
  2. Install side gear shaft holder. Install snap ring. Coat oil seal lip with grease. Using a hammer and Bearing Replacer (09316-60010), install left side oil seal. Using hammer and Seal Replacer (09608-32010), install right side oil seal.


  1. On A-241H, install level gauge guide plate. Tighten bolt to 84 INCH lbs. (10 N.m). On both models, install relief valve and spring. Install oil pump drive rotor and driven rotor.
  2. Install oil pump cover and driven gear stopper. On A-241H, tighten 3 bolts to 84 INCH lbs. (10 N.m). Insert oil pump driven gear to drive rotor. Ensure drive rotor turns smoothly.


  1. Using Bearing Replacer (09316-20011) and Bearing Tool Set (09608-35014), press in right case bearing with an arbor press. Using Bearing Replacer (09316-12010) and Bearing Tool Set (09608-35014), press in left case bearing with an arbor press.
  2. Clean contact surface of ring gear mounting left case. Heat ring gear to about 212°F (100°C) in an oil bath. DO NOT  heat ring above 230°F (110°C). Clean contact surface of ring gear with cleaning solvent. Quickly install ring gear on ring gear mounting left case.
  3. Install following parts to center differential case: side gear thrust washer, differential side left gear, 4 pinion thrust washers, 4 differential pinions, pinion shaft holder and 4 pinion shafts. Install spacer to center differential case. Using a dial indicator, measure side gear backlash while holding one pinion toward case. Backlash on A-241H is .0024-.0087" (.060-.220 mm). If backlash exceeds specification, install the correct thrust washer on the side gears. Refer to the SIDE GEAR THRUST WASHER SPECIFICATIONS  table Also, see Fig 3.
  4. Install differential side right gear. DO NOT  install conical spring washer. Install center differential case. Install thrust washer. Align match marks on left and right cases. Install 12 bolts. Tighten to 72 ft. lbs. (97 N.m). DO NOT  install "O" ring. Using a caliper, measure conical spring washer. Measure thrust clearance of center differential case while holding ring gear mounting case. See Fig 2 and Fig 3 .
  5. Select thrust washer which will ensure backlash is within specification. Install differential side gear and conical spring washer. Ensure correct direction of conical spring washer.
  6. Install center differential case. Install correct thrust washer. Install new "O" ring on left case. Align match marks on right and left case. Install 12 bolts. Tighten to 72 ft. lbs. (97 N.m). Install oil pump drive gear. Install shaft snap ring.
SIDE GEAR THRUST WASHER SPECIFICATIONS

ID Mark Thickness: In. (mm)
None .0315 (0.800)
None .0354 (0.900)
A .0394 (1.000)
B .0413 (1.050)
C .0433 (1.100)
D .0453 (1.150)
E .0472 (1.200)
F .0492 (1.250)
G .0512 (1.300)
H .0531 (1.350)
J .0551 (1.400)
K .0571 (1.450)
L .0591 (1.500)
Fig 1: Exploded View Of Ring Gear Mounting & Center Differential Case
G93G25789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Measuring Center Differential Thrust Clearance
G93J25790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Checking Center Differential Side Gear Thrust Clearance
G93B25792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002


  1. On A-241H, install oil strainer in sleeve. Install clutch control valve sleeve. Apply seal packing Three Bond (1281) to sleeve cover. Install control valve sleeve cover. Tighten bolts to 115 INCH lbs. (13 N.m). On both models, insert shift fork shaft into shift fork. Install ball, spring and head plug. Tighten plug to 18 ft. lbs. (25 N.m). Install shift fork shaft, shift fork and sleeve. Coat lip of new seal with grease. Using a 17-mm socket wrench and hammer, install oil seal into transfer shift lever. Install transfer shift lever. Engage shift fork and transfer shift lever. Install and tighten lock bolts to 35 INCH lbs. (3.9 N.m).
  2. Install "O" rings on solenoid(s). Install center differential control solenoid(s). Tighten to 10 ft. lbs. (14 N.m). On A-241H, install apply tube. DO NOT  bend or damage tubes.
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