Transfer ASSY (4WD): Overhaul

HINT:

COMPONENT:

3MZ-FE ENGINE: See COMPONENTS

2AZ-FE ENGINE: See COMPONENTS

AUTOMATIC TRANSMISSION (U151E/U151F): See COMPONENTS

TRANSFER: See TRANSFER (4WD) 

1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (See  REPLACEMENT  ) 
2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (See  REPLACEMENT  ) 
3. REMOVE TRANSFER CASE NO.1 PLUG 
   1. Remove the transfer case No.1 plug.
   2. Remove the gasket No.1 from the transfer case No.1 plug.
   Fig 1: Identifying Transfer Case No.1 Plug No 2 & Drain Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE TRANSFER CASE NO.2 PLUG 
   1. Remove the transfer case No.2 plug.
   2. Remove the gasket No.2 from the transfer case No.2 plug.
5. REMOVE TRANSFER DRAIN PLUG 
   1. Remove the transfer drain plug and bleed the transfer oil.
   2. Remove the drain gasket from the transfer drain plug.
6. REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) 
   1. Remove the 5 bolts and the stiffener plate RH.
   Fig 2: Locating bolts of Transfer Stiffener Plate RH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE) 
   1. Remove the 3 bolts and the engine mounting bracket RR.
8. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE) (See  REPLACEMENT  ) 
9. REMOVE TRANSFER ASSY 
   1. Remove the 2 bolts and 6 nuts.
   2. Using a plastic hammer, remove the transfer assy from the transaxle assy.
   NOTE:

   • Remove the transfer assy from the transaxle assy without tilting it.
   • When removing the transfer assy, do not hold onto the oil seal parts on both sides of the assy.
   Fig 3: locating 2 bolts & 6 Nuts of Transfer Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE TRANSFER COVER GASKET 
    1. Remove the transfer cover gasket from the transfer assy.
    Fig 4: Locating Transfer Cover Gasket

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE TRANSFER CASE BREATHER PLUG 
    1. Using a screwdriver and a hammer, remove the transfer case breather plug from the transfer case cover No.1.
    NOTE: Be careful not to damage the contact surface of the case cover No.1.
    Fig 5: Locating Transfer Case Breather Plug

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE TRANSFER CASE COVER NO.1 
    1. Remove the 8 bolts.
       Fig 6: Locating 8 Bolts of Transfer Case No.1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the transfer case cover No.1 from the transfer.
    NOTE: Be careful not to damage the contact surfaces of the case and cover.
    Fig 7: Removing Transfer Case Cover No.1 From Transfer

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE BREATHER OIL DEFLECTOR 
    1. Remove the bolt and breather oil deflector from the transfer case cover No.1. 
    Fig 8: Locating Bolt of Breather Oil Deflector

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE TRANSFER DYNAMIC DAMPER 
    1. Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing sub-assy.
    Fig 9: Locating 3 Bolts of Transfer Dynamic Damper

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE TRANSFER CASE STRAIGHT PIN 
    1. Remove the 4 transfer case straight pins from the transfer case.
16. REMOVE TRANSFER & TRANSAXLE SETTING STUD BOLT 
    1. Remove the 4 transfer & transaxle setting stud bolts.
17. FIX TRANSFER ASSY 
    1. Fix the transfer assy to the overhaul attachment.
18. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR 
    1. Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assy.
    Fig 10: Removing Transfer Extension Housing Dust Deflector

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing.

       SST 09308-00010

    NOTE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.
    Fig 11: Removing Transfer Extension Housing Type

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY 
    1. Remove the 4 bolts.
       Fig 12: Locating 4 Bolts of Transfer Extension Housing Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, remove the transfer extension housing sub-assy from the transfer case.
    Fig 13: Removing Transfer Extension Housing Sub-Assy From Transfer Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. INSPECT PRELOAD 
    1. Using SST and a torque wrench, check the initial torque within the backlash range.

       SST 09326-20011

       Torque (preload): 0.9 to 1.4 N.m

       (9 to 14 kgf.cm, 8.0 to 12.4 in..lbf)

       HINT:

       • Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
       • If the value is out of standard range, replace the driven pinion bearing.
       Fig 14: Inspecting Preload Using SST & Torque Wrench

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.

       SST 09326-20011

       Torque: Preload + 0.15 to 0.30 N.m

       (+1.6 to 3.1 kgf.cm, +1.3 to 2.7 in..lbf)

    HINT:

    • Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
    • If the value is out of standard range, overhaul the transfer.
22. INSPECT BACKLASH 
    1. Set the dial indicator perpendicular to the tooth face of the ring gear, fix the driven pinion and inspect the backlash while moving the gear.

       Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.)

    NOTE: Inspect it at 3 points or more on the gear's periphery.

    HINT:

    Write down the result.

    Fig 15: Inspecting Backlash Using Dial Indicator

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION 
    1. Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate several times.
       NOTE: Inspect the tooth contact on the ring gear at 4 places or more.
    2. Proper washer location is shown in the illustration.
    Fig 16: Applying Red Lead Primer & Uniformly To Both Faces Of Ring Gear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 17: Identifying Ring-Gear Tooth Contacts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. REMOVE CTR DIFFERENTIAL LOCK SLEEVE 
    1. Using snap ring pliers, remove the shaft snap ring.
       Fig 18: Removing Shaft Snap Ring

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the CTR differential lock sleeve.

       SST 09308-00010

    Fig 19: Removing CTR Differential Lock Sleeve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. REMOVE O-RING 
    1. Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.
    NOTE: Be careful not to damage the lock sleeve's groove for the O-ring.
    Fig 20: Removing O-Ring From Center Differential Lock Sleeve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. REMOVE TRANSFER CASE OIL SEAL 
    1. Using SST, remove the transfer case oil seal from the case.

       SST 09308-00010

    NOTE: Be careful not to damage the oil-seal-fitted surface of the case.
    Fig 21: Removing Transfer Case Oil Seal From Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST, remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assy.

       SST 09308-00010

    NOTE: Be careful not to damage the oil-seal-fitted surface of the retainer.
    Fig 22: Removing Transfer RH Bearing Retainer Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY 
    1. Remove the 7 bolts from the transfer RH bearing retainer sub-assy.
       Fig 23: Locating 7 Bolts Of Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver and a hammer, create a clearance between the transfer RH bearing retainer sub-assy and the transfer case.
       NOTE: Be careful not to damage the transfer RH bearing retainer sub-assy and the transfer case.
       Fig 24: Creating A Clearance Between Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the transfer RH bearing retainer subassy from the transfer case.

       SST 09520-10021

    Fig 25: Removing Transfer RH Bearing Retainer Sub-Assy From Transfer Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. REMOVE O-RING 
    1. Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assy.
    NOTE: Be careful not to damage the retainer's grooves for the O-rings.
    Fig 26: Using A Screwdriver With Tip Protected By Vinyl Tape

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Fix the transfer RH bearing retainer sub-assy in a vise.
    2. Using SST, remove the center differential case tapered roller bearing RH outer race, transfer ring gear mounting case washer No.2 and right bearing retainer oil seal No.2 from the transfer RH bearing retainer sub-assy.

       SST 09308-00010

    NOTE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer sub-assy.
    Fig 27: Removing Center Differentia Case Tapered Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. REMOVE SIDE GEAR SHAFT HOLDER BEARING 
    1. Using snap ring pliers, remove the side gear shaft holder hole snap ring.
    2. Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assy.
    Fig 28: Removing Side Gear Shaft Holder Hole Snap Ring

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. REMOVE TRANSFER RING GEAR MOUNTING CASE 
    1. Remove the transfer ring gear mounting case from the transfer case.
    Fig 29: Removing Transfer Ring Gear Mounting Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. LH side:

       Using SST, remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.

       SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00420)

       NOTE: Apply grease to the screw thread and tip of the SST before use.
       Fig 30: Removing Inner Race of Center Differential; Case Tapered Roller Bearing (LH)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.

       SST 09950-00020, 09950-00030, 09950-60010 (09951-00430)

       NOTE: Apply grease to the screw thread and tip of the SST before use.
       Fig 31: Removing Roller And Remaining Inner Races Of Center Differential Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. RH side:

       Using SST, remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.

       SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)

       NOTE: Apply grease to the screw thread and tip of the SST before use.
       Fig 32: Removing Inner Race of Center Differential Case Tapered Roller Bearing (RH)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.

       SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)

       NOTE: Apply grease to the screw thread and tip of the SST before use.
    Fig 33: Removing Roller & Remaining Inner Races of Center Differential Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
34. REMOVE RING GEAR 
    1. Put matchmarks on the transfer ring gear mounting case and the ring gear.
    2. Remove the 12 bolts.
       Fig 34: Identifying Matchmarks on Transfer Ring Gear Mounting Case And Ring Gear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, remove the ring gear by tapping around its periphery.
       NOTE: Do not damage the teeth of the ring gear.

       HINT:

       If the runout is too large, replace the transfer ring rear mounting case.

    Fig 35: Removing Ring Gear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
35. INSPECT RUNOUT OF TRANSFER RING GEAR MOUNTING CASE 
    1. Using a dial indicator, check the transfer ring gear mounting case runout.

       Maximum runout: 0.03 mm (0.0012 in.)

       HINT:

       If the runout is too large, replace the center differential control coupling assy or transfer ring gear mounting case.

    Fig 36: Inspecting Run-Out of Transfer Ring Gear Mounting Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
36. REMOVE DRIVEN PINION 
    1. Using SST and a hammer, unstake the transfer gear nut.

       SST 09930-00010

       Fig 37: Unstaking Transfer Gear Nut

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the transfer gear nut.

       SST 09326-20011, 09556-16030

       Fig 38: Removing Transfer Gear Nut

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer.
       NOTE:

       • Put a shop rag around to help prevent the driven pinion from being dropped.

         Place something like wooden blocks under the case to keep it level.

    Fig 39: Removing Driven Pinion, Transfer Driven Pinion Rear Bearing Inner Race

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
37. REMOVE TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.

       SST 09950-00020

    Fig 40: Removing Transfer Driven Pinion Front Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
38. REMOVE TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 points to remove it from the transfer case.
    Fig 41: Removing Transfer Driven Pinion Front Bearing(LH)

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
39. REMOVE TRANSFER OUTPUT WASHER 
    1. Remove the ring gear mounting case plate washer from the transfer case.
40. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using a brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.
    Fig 42: Removing Center Differential Case Tapered Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
41. REMOVE RING GEAR MOUNTING CASE PLATE WASHER 
    1. Remove the transfer output washer from the transfer case.
42. REMOVE TRANSFER DRIVEN PINION REAR BEARING 
    1. Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.
    Fig 43: Removing Transfer Driven Pinion Rear Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
43. INSTALL TRANSFER DRIVEN PINION REAR BEARING 
    1. Using SST and a press, install the transfer driven pinion rear bearing outer race to the transfer case.

       SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)

    NOTE: Place something like wooden blocks under the case to keep its level.
    Fig 44: Installing Transfer Driven Pinion Rear Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
44. INSTALL TRANSFER OUTPUT WASHER 
    1. Install the transfer output washer to the transfer case.

       HINT:

       Reuse the washer.

45. INSTALL TRANSFER DRIVEN PINION FRONT BEARING 
    1. Install the transfer driven pinion front bearing outer race to the transfer case with SST, bolt and nut.

       SST 09950-60020 (09951-00750, 09951-00770, 09951-00810), 09316-60011 (09316-00061)

    Fig 45: Installing Transfer Driven Pinion Front Bearing Outer Race To Transfer Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
46. INSTALL RING GEAR MOUNTING CASE PLATE WASHER 
    1. Install the ring gear mounting case plate washer to the transfer case.

       HINT:

       Reuse the washer.

47. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using SST and a press, install the center differential case tapered roller bearing LH outer race to the transfer case.
       Fig 46: Installing Center Differential Case Tapered Roller

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       SST 09950-70010 (09951-07200), 09316-60011 (09316-00021)

48. INSTALL TRANSFER DRIVEN PINION FRONT BEARING 
    1. Using SST and a press, install the transfer driven pinion front bearing inner race to the driven pinion.

       SST 09316-6001 1 (09316-00041)

    Fig 47: Installing Transfer Driven Pinion Front Bearing Inner Race To Driven Pinion

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
49. INSTALL DRIVEN PINION 
    1. Install the driven pinion to the transfer case.
       Fig 48: Installing Driven Pinion To Transfer Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new transfer pinion bearing spacer and a new transfer driven pinion rear bearing inner race to the driven pinion.
       Fig 49: Installing A New Transfer Pinion Bearing Spacer

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, tighten a new transfer gear nut (at a standard torque.)

       SST 09326-2001 1, 09556-16030

       Torque: 

       277 to 378 N.m (2,820 to 3,855 kgf.cm, 204 to 279 ft.lbf) 

       Fig 50: Tightening New Transfer Gear Nut

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Do not stake the transfer gear nut.

       HINT:

       Use a torque wrench with a fulcrum length of 750 mm (29.53 in.)

50. INSPECT AND ADJUST DRIVEN PINION PRELOAD 
    1. Using SST and a torque wrench, measure the initial torque of the driven pinion.

       Preload (at starting): 

       New bearing: 

       1.1 to 1.6 N.m (11 to 16 kgf.cm, 9.7 to 14.2 in..lbf) Used bearing: 

       0.9 to 1.4 N.m (9 to 14 kgf.cm, 8.0 to 12.4 in..lbf) 

       HINT:

       Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)

       NOTE: Measure preload after rotating the bearing both clockwise and counterclockwise to make it fit.
       Fig 51: Measuring Initial Torque of Driven Pinion

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. If the preload is too large, replace the transfer pinion bearing spacer with a new one.
    3. If the preload is too small, repeatedly adjust the preload by tightening the transfer gear nut 5 to 10 degrees at a time until the standard value is obtained.
    4. If the preload is insufficient, even though the tightening torque of the transfer gear nut exceeds the maximum of the standard value, loosen the transfer gear nut and apply gear oil SAE 90 (GL-5) to the transfer gear nut and the screw thread and the base of the driven pinion. And then repeat the preceding operation. If the tightening torque is smaller than the standard, replace the transfer pinion bearing spacer with a new one and adjust it.

       SST 09326-2001 1, 09556-16030

       Torque: 378 N.m (3,855 kgf.cm, 279 ft.lbf) 

51. INSTALL RING GEAR 
    1. Completely remove grease and moisture on the contact surfaces of the ring gear and the transfer ring gear mounting case.
    2. Heat the ring gear in boiling water from 90 to 100°C (194 to 212°F).
    3. Carefully take the ring gear out of the boiling water.
       Fig 52: Taking Out Ring Gear From Boiling Water

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the matchmarks on the ring gear and transfer ring gear mounting case and quickly assemble them.
    5. Tighten the12 bolts.

       Torque: 78 N.m (790 kgf.cm, 57 ft.lbf) 

       NOTE:

       • Tighten the bolts in diagonal order in splitting several times.
       • After the ring gear has well cooled down, fully tighten the bolts.
       • Make the bolt heads in order to check if they are retightened or not.
    Fig 53: Aligning Matchmarks On Ring Gear And Transfer Ring Gear Mounting Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
52. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. RH side:

       Using SST and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case.

       SST 09506-35010, 09950-60010 (09951-00430)

       NOTE: When replacing the inner race, replace it together with the outer race.
       Fig 54: Installing Inner Race of Center Differential Case Tapered Roller Bearing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. LH side:

       Using SST and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case.

       Fig 55: Installing Inner Race Of Center Differential Case Tapered Roller Bearing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       SST 09223-00010

       NOTE: When replacing the inner race, replace it together with the outer race.
53. INSTALL TRANSFER RING GEAR MOUNTING CASE 
    1. Install the transfer ring gear mounting case to the transfer case.
       Fig 56: Installing Transfer Ring Gear Mounting Case to Transfer Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Damage to the spline, the bearing's rotating surface and gear face may cause a decrease in their strength. Care should be taken when installing them.
54. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2 
    1. Install the transfer ring gear mounting case washer No.2 to the transfer RH bearing retainer sub-assy.

       HINT:

       Reuse the washer.

55. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using SST and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer sub-assy.

       SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)

    Fig 57: Installing Center Differential Case Tapered Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
56. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY 
    1. Place the transfer with the face where the transfer RH bearing retainer sub-assy is to be installed facing up.
    2. Center-align the transfer ring gear mounting case and the transfer case.
       Fig 58: Identifying Transfer Rh Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Insert the SST into the transfer RH bearing retainer subassy.

       SST 09387-00090

       NOTE: Insert SST straight in order not to damage the oil seal lip.
       Fig 59: Inserting SST straight into Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Insert the transfer RH bearing retainer sub-assy together with the SST into the transfer case.
       NOTE: Interference between the case and retainer, and between the transfer ring gear mounting case and SST should be carefully avoided.

       HINT:

       If the retainer cannot be inserted, tap it in with a plastic hammer.

       Fig 60: Inserting Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. After inserting the transfer RH bearing retainer sub-assy into the transfer case, remove the SST.
       Fig 61: Removing SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the 7 bolts.

       Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

    Fig 62: Locating Bolts of Transfer RH Bearing Retainer Sub-Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
57. INSPECT BACKLASH 
    1. Set the dial indicator perpendicular to the ring gear face, fix the driven pinion, and check backlash by moving the ring gear.

       Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.) 

       NOTE: Measure it at 3 points or more on the ring gear periphery.
    2. If the measured value is out of standard, select a proper washer for the center differential case tapered roller bearing on the LH side from the table below and install it to obtain the standard value.
       Fig 63: Checking Backlash By Mounting Ring Gear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       BACKLASH STANDARD VALVE
       
       

       Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
       AA	2.07 (0.0814)	AB	2.10 (0.0826)	AC	2.13 (0.0838)
       BA	2.16 (0.0850)	BB	2.19 (0.0862)	BC	2.22 (0.0874)
       CA	2.25 (0.0885)	CB	2.28 (0.0897)	CC	2.31 (0.0909)
       DA	2.34 (0.0921)	DB	2.37 (0.0933)	DC	2.40 (0.0944)
       EA	2.43 (0.0956)	EB	2.46 (0.0968)	EC	2.49 (0.0980)
       FA	2.52 (0.0992)	FB	2.55 (0.1003)	FC	2.58 (0.1015)
       GA	2.61 (0.1027)	GB	2.64 (0.1039)	GC	2.67 (0.1051)
       HA	2.70 (0.1062)	HB	2.73 (0.1074)	HC	2.76 (0.1086)
       JA	2.79 (0.1098)	JB	2.82 (0.1110)	JC	2.85 (0.1122)
       KA	2.88 (0.1133)	KB	2.91 (0.1145)	KC	2.94 (0.1157)
       LA	2.97 (0.1169)	LB	3.00 (0.1181)	-	-

       HINT:

       When the backlash is larger or smaller than the standard, select a thinner or thicker washer respectively.

    3. Ring gear mounting case plate washer location is shown in the illustration.
    Fig 64: Locating Ring Gear Mounting Case Piece Washer

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
58. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION 
    1. Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate it several times.
       NOTE: Check the tooth contact on the ring gear at 4 places or more.
    2. Observe the pattern shown by red lead primer.
       Fig 65: Applying Red Lead Primer Thinly & Uniformly to both Faces of Ring Gear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       Fig 66: Identifying Ring Gear Tooth Contacts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. In case of poor tooth contact, select a washer for the driven pinion bearing front side from the following table and replace it.
       NOTE: If the washer thickness is changed, the backlash will be also changed.
       BACKLASH STANDARD VALVE
       
       

       Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
       AA	1.20 (0.0472)	AC	1.22 (0.0480)	BB	1.24 (0.0488)
       CA	1.26 (0.0496)	CC	1.28 (0.0503)	DB	1.30 (0.0511)
       EA	1.32 (0.0519)	EC	1.34 (0.0527)	FB	1.36 (0.0535)
       GA	1.38 (0.0543)	GC	1.40 (0.0551)	HB	1.42 (0.0559)
       JA	1.44 (0.0566)	JC	1.46 (0.0574)	KB	1.48 (0.0582)
       LA	1.50 (0.0590)	LC	1.52 (0.0598)	MB	1.54 (0.0606)
       NA	1.56 (0.0614)	NC	1.58 (0.0622)	PB	1.60 (0.0629)
       QA	1.62 (0.0637)	QC	1.64 (0.0645)	-	-

    4. The location of the transfer output washer for tooth contact adjustment is shown in the illustration.
    Fig 67: Locating Transfer Output Washer

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
59. ADJUST TOTAL PRELOAD 
    1. Using SST and a torque wrench, measure the initial torque with the driven pinion being contact with the ring gear face.

       SST 09326-2001 1

       Torque:

       New bearing:

       Driven pinion preload +0.2 to 0.4 N.m (+2.3 to 3.9 kgf.cm, 1.8 to 3.5 in..lbf) Used bearing:

       Driven pinion preload +0.15 to 0.30 N.m (+1.6 to 3.1 kgf.cm, 1.3 to 2.7 in..lbf)

       NOTE: Before measurement, rotate the bearing in both directions several times to make it fit.

       HINT:

       Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).

    2. If the value is out of standard range, select the washer for the center differential case tapered roller bearing RH side from the following table and replace it.
       Fig 68: Measuring Initial Torque With Driven Pinion Being Contact

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       WASHER THICKNESS SPECIFICATION
       
       

       Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)	Mark	Washer Thickness mm (in.)
       AA	1.47 (0.0578)	AB	1.50 (0.0590)	AC	1.53 (0.0602)
       BA	1.56 (0.0614)	BB	1.59 (0.0625)	BC	1.62 (0.0637)
       CA	1.65 (0.0649)	CB	1.68 (0.0661)	CC	1.71 (0.0673)
       DA	1.74 (0.0685)	DB	1.77 (0.0696)	DC	1.80 (0.0708)
       EA	1.83 (0.0720)	EB	1.86 (0.0732)	EC	1.89 (0.0744)
       FA	1.92 (0.0755)	FB	1.95 (0.0767)	FC	1.98 (0.0779)
       GA	2.01 (0.0790)	GB	2.04 (0.0803)	GC	2.07 (0.0814)
       HA	2.10 (0.0826)	HB	2.13 (0.0838)	HC	2.16 (0.0850)
       JA	2.19 (0.0862)	JB	2.22 (0.0874)	JC	2.25 (0.0885)
       KA	2.28 (0.0897)	KB	2.31 (0.0909)	KC	2.34 (0.0921)
       LA	2.37 (0.0933)	LB	2.40 (0.0944)	LC	2.43 (0.0956)
       MA	2.46 (0.0968)	MB	2.49 (0.0980)	MC	2.52 (0.0992)
       NA	2.55 (0.1003)	NB	2.58 (0.1015)	-	-

    3. The location of the transfer ring gear mounting case washer No.2 for preload adjustment is shown in the illustration.
       Fig 69: Locating Transfer Ring Gear Mounting Case Washer No.2

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a chisel, stake the transfer gear nut.
    Fig 70: Staking Transfer Gear Nut

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
60. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY 
    1. Remove the 7 bolts from the transfer RH bearing retainer sub-assy.
       Fig 71: Locating Bolts of Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver and a hammer, make a opening between the transfer RH bearing retainer sub-assy and the transfer case.
       NOTE: Be careful not to damage the transfer RH bearing retainer sub-assy and the transfer case.
       Fig 72: Making a Opening Between Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the transfer RH bearing retainer subassy from the transfer case.

       SST 09520-10021

    Fig 73: Removing Transfer RH Bearing Retainer SubAssy From Transfer Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
61. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Fix the transfer RH bearing retainer sub-assy in a vise.
    2. Using SST, remove the center differential case tapered roller bearing RH outer race and transfer ring gear mounting case washer No.2 from the transfer RH bearing retainer sub-assy.

       SST 09308-00010

    Fig 74: Removing Center Differential Case Tapered Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
62. INSTALL SIDE GEAR SHAFT HOLDER BEARING 
    1. Install the side gear shaft holder bearing to the transfer RH bearing retainer sub-assy.
    2. Using snap ring pliers, install the side gear shaft holder hole snap ring.

       HINT:

       Check that the side gear shaft holder hole snap ring fits in the groove of the transfer RH bearing retainer sub-assy.

    Fig 75: Installing Side Gear Shaft Holder Snap Ring

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
63. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST and a press, install the transfer RH bearing retainer oil seal No.2 to the transfer RH bearing retainer sub-assy.

       SST 09950-60010 (09951-00350, 09951-00560, 09952-06010), 09950-70010 (09951-07150)

       NOTE: Carefully press-fit so that the oil seal will not be tilted.
       Fig 76: Installing Transfer RH Bearing Retainer Oil Seal

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply small amount of MP grease No.2 to the oil seal lip.
64. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2 
    1. Install the selected transfer ring gear mounting washer No.2 to the transfer RH bearing retainer subassy.
65. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING 
    1. Using SST and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer sub-assy.

       SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)

    Fig 77: Installing Center Differential Case Tapered Roller Bearing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
66. INSTALL O-RING 
    1. Coat 2 new O-rings with hypoid gear oil.
    2. Install the 2 O-rings to the transfer RH bearing retainer sub-assy.
    Fig 78: Installing O-Ring To Transfer Rh Bearing Retainer Sub-Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Be careful not to twist the O-ring but to fit it properly in the retainer's groove.
67. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY 
    1. Place the transfer with the surface where the transfer RH bearing retainer sub-assy is facing up.
    2. Align the centers of the transfer ring gear mounting case and the transfer case.
       Fig 79: Identifying Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Insert SST into the transfer RH bearing retainer sub-assy.

       SST 09387-00090

       Fig 80: Inserting SST Into Transfer Rh Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Insert SST straight in order not to damage the oil seal.
    4. Insert the transfer RH bearing retainer sub-assy together with SST into the transfer case.
       NOTE:

       • Avoid interference between the case and the retainer, and between the SST and the transfer ring gear mounting case.
       • Carefully check the retainer's O-ring for damage and incorrect fitting.
       Fig 81: Inserting Transfer RH Bearing Retainer Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       If the retainer cannot be inserted into the case, tap it in with a plastic hammer.

    5. After inserting the transfer RH bearing retainer sub-assy into the transfer case, remove the SST.
       Fig 82: Removing SST

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the 7 bolts.

       Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

    Fig 83: Locating Bolts Of Transfer RH Bearing Retainer Sub-Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
68. INSPECT TOTAL PRELOAD 
    1. Using SST and a torque wrench, measure the initial torque with the driven pinion being in contact with the ring gear face.

       SST 09326-2001 1

       Torque: 

       New bearing: 

       Driven pinion preload +0.2 to 0.4 N.m (+2.3 to 3.9 kgf.cm, 1.8 to 3.5 in..lbf) Used bearing: 

       Driven pinion preload +0.15 to 0.30 N.m (+1.6 to 3.1 kgf.cm, +1.3 to 2.7 in..lbf) 

    Fig 84: Measuring Initial Torque With Driven Pinion

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    • Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
    • If the preload is too large, inspect the transfer RH bearing retainer sub-assy.
69. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL 
    1. Using SST, install the transfer RH bearing retainer oil seal to the transfer RH bearing retainer sub-assy to the position as shown in the illustration.

       SST 09223-4601 1

       NOTE: Install the oil seal carefully so that it will not be tilted.
    2. Apply MP grease to the oil seal lip.
    Fig 85: Installing Transfer RH Bearing Retainer Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
70. INSTALL TRANSFER CASE OIL SEAL 
    1. Using SST, install the transfer case oil seal to the transfer case at the position as shown as in the illustration.

       SST 09387-00010, 09950-70010 (09951-07150)

       NOTE: Install the oil seal carefully so that it will not be tilted.
    2. Apply small amount of MP grease to the oil seal lip.
    Fig 86: Installing Transfer Case Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
71. INSTALL CTR DIFFERENTIAL LOCK SLEEVE 
    1. Coat a new O-ring with hypoid gear oil.
    2. Install the O-ring to the CTR differential lock sleeve.
       NOTE: Be careful not to twist the O-ring but to fit it properly in the retainer's groove.
       Fig 87: Installing O-Ring To Center Differential Lock Sleeve

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the CTR differential lock sleeve to the transfer case.

       SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)

       Fig 88: Installing Center Differential Lock Sleeve To Transfer Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using snap ring pliers, install the shaft snap ring.
       NOTE: Check that the snap ring is fitted in the groove of the ring gear mounting case.
    Fig 89: Installing Shaft Snap Ring

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
72. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL 
    1. Using SST, install the transfer extension housing type T oil seal to the transfer extension housing at the position as shown in the illustration.

       SST 09950-60010 (09951-00380, 09951-00580, 09952-06010), 09950-70010 (09951-07150)

       Fig 90: Installing Transfer Extension Housing Type T Oil Seal

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Install the oil seal carefully so that it will not be tilted.
    2. Apply small amount of MP grease No.2 to the oil seal lip.
73. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR 
    1. Using SST and a press, install a new transfer extension housing dust deflector to the transfer extension housing sub-assy.
       Fig 91: Installing Transfer Extension Housing Dust Deflector

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)

74. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSY 
    1. Apply sealant 1281 to the transfer extension housing sub-assy in continuous beaded form of 1.2 mm diameter as shown in the illustration.
       Fig 92: Applying Sealant Transfer Extension Housing Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE:

       • Wipe any grease off from the attaching surfaces.
       • Install the transfer extension housing sub-assy within 10 minutes after applying the sealant.
    2. Install the transfer extension housing sub-assy to the transfer case with the 4 bolts.

       Torque: 26 N.m (260 kgf.cm, 19 ft.lbf) 

    3. Remove the transfer assy from the overhaul attachment.
    Fig 93: Locating 4 Bolts of Transfer Extension Housing Sub-Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
75. INSTALL TRANSFER & TRANSAXLE SETTING STUD BOLT 
    1. Install the 4 transfer & transaxle setting stud bolts to the parts of the transfer case as shown in the illustration.

       Torque: 39 N.m (400 kgf.cm, 30 ft.lbf) 

       NOTE: Install the sealant-coated side of the transfer & transaxle stud bolt to the transfer case.
    Fig 94: Identifying Transfer & Transaxle Setting Stud Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
76. INSTALL TRANSFER CASE STRAIGHT PIN 
    1. Using a plastic hammer, install the 4 transfer case straight pins to the transfer case as shown in the illustration.
    Fig 95: Identifying Transfer Case Straight Pins

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
77. INSTALL TRANSFER DYNAMIC DAMPER 
    1. Install the transfer dynamic damper to the transfer extension housing sub-assy with the 3 bolts.

       Torque: 26 N.m (260 kgf.cm, 19 ft.lbf) 

    Fig 96: Locating 3 Bolts of Transfer Extension Housing Sub-Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
78. INSTALL BREATHER OIL DEFLECTOR 
    1. Install the breather oil deflector to the transfer case cover No.1 with the bolt.

       Torque: 6.5 N.m (66 kgf.cm, 57 in..lbf) 

       NOTE: Be careful of the direction of the deflector's fold.
    Fig 97: Locating Bolt of Breather Oil Deflector to Transfer Case Cover No.1

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
79. INSTALL TRANSFER CASE COVER NO.1 
    1. Apply sealant 1281 to the transfer case cover No.1 in a continuous bead of 1.2 mm diameter as shown in the illustration.
       Fig 98: Applying Sealant Transfer Case Cover No.1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE:

       • Wipe any grease off from the attaching surfaces.
       • Install the transfer case cover No.1 within 10 minutes after application of the sealant.
    2. Install the transfer case cover No.1 to the transfer case with the 8 bolts.

       Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

    Fig 99: Locating Bolts of Transfer Case Cover No.1

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
80. TRANSFER CASE BREATHER PLUG 
    1. Using SST and a hammer, install the transfer case breather plug to the transfer case cover No.1.

       SST 09612-10061)

    Fig 100: Installing Transfer Case Breather Plug To Transfer Case Cover No.1

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
81. INSTALL TRANSFER COVER GASKET 
    1. Install a new transfer cover gasket to the transfer case.
    Fig 101: Locating Transfer Cover Gasket

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
82. INSTALL TRANSFER ASSY 
    1. Apply sealant 1281 to the transaxle assy and the transfer assy in continuous beaded form of 1.2 mm diameter as shown in the illustration.
       NOTE:

       • Wipe any grease off from the attaching surfaces.
       • Install it within 10 minutes after applying the sealant.
       • Sealant stuck on the gasket, case oil seal and driving plug may cause oil leakage and seizure due to oil shortage. Care must be taken.
       Fig 102: Locating Driving Plug, Sealant & Gasket

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transfer assy to the transaxle assy with the 2 bolts and 6 nuts.

       Torque: 69 N.m (700 kgf.cm, 51 ft.lbf) 

       NOTE:

       • Check that the gasket is installed to the transfer assy before installing them to the transaxle assy.
       • Install the transfer assy to the transaxle assy without tilting.
       • When moving the transfer assy, do not hold the oil seal on the both sides.
    Fig 103: Locating Bolts & Nuts of Transfer Assy to Transaxle Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
83. INSTALL ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE) 
    1. Install the engine mounting bracket RR with the 3 bolts.

       Torque: 64 N.m (652 kgf.cm, 47 ft.lbf) 

    Fig 104: Locating Bolts of Stiffener Plate RH

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
84. INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) 
    1. Install the stiffener plate RH with the 5 bolts.

       Torque: 34 N.m (350 kgf.cm, 25 ft.lbf) 

85. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE) (See  REPLACEMENT  ) 
86. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (See  REPLACEMENT  ) 
87. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (See  REPLACEMENT  ) 
88. INSTALL TRANSFER DRAIN PLUG 
    1. Install the transfer drain plug with a new drain gasket.

       Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

89. INSTALL TRANSFER CASE NO.2 PLUG 
    1. Install the transfer case No.2 plug with a new gasket No.2.

       Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

90. INSTALL TRANSFER CASE NO.1 PLUG 
    1. Add oil up to 0 to 5 mm below the lower side of the plug hole.

       Oil quantity: 0.9 L (0.95 US qts, 0.79 lmp. qts) 

       HINT:

       When adding oil, pour it slowly.

    2. Install the transfer case No.1 plug with a new gasket No.1.

       Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

    Fig 105: Installing Transfer Drain Plug, Case No. 2 Plug & Case No. 1 Plug

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002