2002 Lexus LX 470FACTORY OEM SERVICE PROCEDURE

Transfer Assembly: Reassembly

  1. INSPECT SHIFT FORK NO. 2 AND CLUTCH SLEEVE CLEARANCE 

    Using a feeler gauge, measure the clearance between the shift fork No. 2 and clutch sleeve.

    Fig 1: Measuring Clearance Between Shift Fork No 2 And Clutch Sleeve
    G03322274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Standard clearance: 

    0.10 - 0.40 mm (0.0039 - 0.0157 in.) 

    Maximum clearance: 

    0.40 mm (0.0157 in.) 

  2. INSTALL THE BEARING RACE (FOR THE OUTPUT SHAFT) 

    Using SST and a press, install the bearing race.

    Fig 2: Installing Bearing Race For Output Shaft
    G03322275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09316-60011 (09316-00011,09316-00031), 09950-60020 (09951-00890)

  3. INSTALL THE BEARING RACE (FOR THE IDLER GEAR) 

    Using SST and a press, install the bearing race.

    Fig 3: Installing Bearing Race For Idler Gear
    G03322276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09316-60011 (09316-00011,09316-00031), 09950-60020 (09951-00790)

  4. INSTALL OIL RECEIVER TO FRONT CASE 

    Install the oil receiver and bolt.

    Fig 4: Installing Oil Receiver Bolt
    G03322277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

  5. INSTALL SHIFT OUTER LEVER AND INNER LEVER 
    1. Install the shift inner lever, washer and outer lever to the front case.
    2. Using a pin punch, hammer and socket wrench, tap in the lever lock pin.
      3. Fig 5: Installing Lever Lock Pin
      G03322278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the washer and nut to the shift outer lever.

      Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

  6. ASSEMBLE SHIFT FORK NO. 1 AND SHIFT FORK NO. 1 SHAFT 
    1. Assemble the shift fork No. 1 and shift fork No. 1 shaft.
      2. Fig 6: Installing Slotted Spring Pin
      G03322279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, drive in the slotted spring pin.
  7. INSTALL IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND SHIFT FORK NO. 1 SHAFT TO FRONT CASE 
    Fig 7: Installing Idler Gear Assembly With Center Differential Assembly
    G03322280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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