Part 2

OVERHAUL
51. INSTALL DRIVEN PINION





a. Install the driven pinion to the case.





b. Install a new bearing spacer and a new bearing rear to the driven pinion.





c. Using SST, tighten a new gear nut with a standard torque.
SST 09326-20011, 09556-16030
Torque: 327 Nm (3,334 kgf-cm, 241 ft. lbs.)

NOTICE: Do not stake the gear nut.





52. INSPECT AND ADJUST DRIVEN PINION PRELOAD
a. Using SST and a torque wrench, measure the initial torque of the driven pinion.
SST 09326-20011
Preload (at starting):
New bearing: 0.9 - 1.4 Nm (9 - 14 kgf-cm, 8.0 - 12.0 inch lbs.)
Used bearing: 0.8 - 1.1 Nm (8 - 11 kgf-cm, 7.0 - 9.7 inch lbs.)

NOTICE: Measure it after rotating the bearing in both advance and reverse directions to make it fit.

b. If the preload is too large, replace the bearing spacer with new one.
c. If the preload is too small, repeatedly adjust the preload by tightening the lock nut 5 to 10 degrees at a time until the standard value is obtained.
d. If the preload is insufficient even though the tightening torque of the lock nut exceeds the maximum of the standard value, loosen the lock nut and apply antirust oil or gear oil SAE 90 (GL-5) to the lock nut and the screw thread and base of the driven pinion. And then repeat the preceding operation. If the tightening torque is smaller than the standard, replace the bearing spacer with new one and adjust it.
SST 09326-20011, 09556-16030
Torque: 378 Nm (3,855 kgf-cm, 279 ft. lbs.)
53. INSTALL RING GEAR





a. Heat the ring gear in boiling water to 90 - 100°C (194 - 212°F).
b. Completely remove grease and moisture on the mating surfaces of the ring gear and the center differential control coupling assy.





c. Align the matchmarks on the ring gear and center differential control coupling assy and quickly assemble them.
d. Tighten the 12 bolts.
Torque: 77.5 Nm (791 kgf-cm, 57 ft. lbs.)
54. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING





a. RH side:
Using SST and a press, install the inner race of the center differential case tapered roller bearing to the center differential control coupling assy.
SST 09506-35010, 09950-00010 (09951-00430)

NOTICE: When replacing the inner race, replace the outer race, too.





b. LH side:
Using SST and a press, install the inner race of the center differential case tapered roller bearing to the center differential control coupling assy.
SST 09223-00010

NOTICE: When replacing the inner race, replace the outer race, too.





55. INSTALL CENTER DIFFERENTIAL CONTROL COUPLING ASSY
a. Install the center differential control coupling assy to the case.

NOTICE: Damage to the spline, bearing's rotating surface and gear face may cause decrease in their strength. Care should be taken at the time of installation.

56. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO. 2

HINT: Reuse the washer used before disassembly.





57. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST and a press, install the outer race to the right bearing retainer.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
58. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY





a. Put the installation surface for the right bearing retainer of the transfer case upward.
b. Center-align the center differential control coupling assy and the case.





c. Insert the SST into the right bearing retainer.
SST 09387-00090

NOTICE: Insert SST straight in order not to damage the oil seal lip.





d. Insert the right bearing retainer together with the SST into the case.

NOTICE: Hard interference between the case and retainer, and between the center differential control coupling assy and SST should be carefully avoided.

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





e. After inserting the right bearing retainer into the case, remove the SST.





f. Tighten the 7 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
59. INSPECT BACKLASH





a. Set the dial gauge perpendicular to the ring gear face, fix the driven pinion, and check the backlash by moving the ring gear.
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)

NOTICE: Measure it at 3 points or more on the ring gear periphery.








b. If the measured value is out of the standard, select a proper washer for the center differential case, tapered roller bearing on the LH side from the table and install it to obtain the standard value.

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





c. Proper washer location is shown in the illustration.
60. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION





a. Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate it several times.

NOTICE: Check the tooth contact on the ring gear at 4 places or more.





b. Observe the pattern shown by red lead primer.








c. In the case of faulty tooth contact, select a washer for the driven pinion bearing front side from the following table and reinstall it.

NOTICE: If the washer thickness is changed, the backlash will be also changed.





d. The location of the washer for tooth contact adjustment is shown in the illustration.
61. ADJUST TOTAL PRELOAD





a. Using SST and a torque wrench, measure the initial torque with the driven pinion being contact with the ring gear face.
SST 09326-20011
Torque:
New bearing: 0.2 - 0.4 Nm (2 - 4 kgf-cm, 1.7 - 3.5 inch lbs.)
Used bearing: 0.1 - 0.3 Nm (1 - 3 kgf-cm, 0.9 - 2.7 inch lbs.)

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








b. If the value is out of the standard range, select the washer for the center differential case tapered roller bearing RH side from the following table and reinstall it.





c. The location of the washer for preload adjustment is shown in the illustration.





d. Using a chisel, stake the gear nut.
62. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY





a. Remove the 7 bolts from the right bearing retainer.





b. Using a screwdriver and a hammer, make a clearance between the right bearing retainer and the transfer case.





c. Using SST, remove the right bearing retainer from the transfer case.
SST 09520-10021





63. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Hold the right bearing retainer in a vise.
b. Using SST, remove the outer race and washer from the right bearing retainer.
SST 09308-00010





64. INSTALL SIDE GEAR SHAFT HOLDER BEARING
a. Install the side gear shaft holder bearing to the right bearing retainer.
b. Using a snap ring pliers, install the side gear shaft holder hole snap ring.

HINT: Check that the snap ring is fit in the groove of the retainer.





65. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
a. Using SST and a press, install the oil seal to the right bearing retainer.
SST 09950-60010 (09951-00350, 09951-00560, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Carefully press-fit so that the oil seal will not be tilted.

b. Apply small amount of MP grease No. 2 to the oil seal lid.
66. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO. 2
a. Install the selected ring gear mounting washer to the right bearing retainer.





67. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST and a press, install the outer race to the right bearing retainer.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)





68. INSTALL D-RING
a. Apply hypoid gear oil to a new O-ring.
b. Install the O-ring to the right bearing retainer.

NOTICE: Be careful not to twist the O-ring and fit it into the retainer's groove properly.

69. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY





a. Place the transfer with the face where the right bearing retainer is to be installed facing up.
b. Center-align the center differential control coupling assy and the case.





c. Insert SST into the right bearing retainer.
SST 09387-00090

NOTICE: Insert SST straight in order not to damage the oil seal.





d. Insert the right bearing retainer together with SST into the case.

NOTICE:
^ Prevent hard interference between the case and the retainer, and between the SST and the center differential control coupling assy.
^ Carefully check for damage and incorrect fitting of the retainer's O-ring.

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





e. After inserting the right bearing retainer into the case, remove the SST.





f. Tighten the 7 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)





70. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, measure the initial torque with the driven pinion being contact with the ring gear face.
SST 09326-20011
Torque:
New bearing: 0.2 - 0.4 Nm (2 - 4 kgf-cm, 1.7 - 3.5 inch lbs.)
Used bearing: 0.1 - 0.3 Nm (1 - 3 kgf-cm, 0.9 - 2.7 inch lbs.)





71. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
a. Using SST, drive the oil seal into the right bearing retainer to the position shown in the illustration.
SST 09223-46011

NOTICE: Drive it in carefully so that it will not be tilted.

b. Apply small amount of MP grease NO. 2 to the oil seal lip.





72. INSTALL TRANSFER CASE OIL SEAL
a. Using SST, drive the case oil seal into the case to the position shown in the illustration.
SST 09387-00010, 09950-70010 (09951-07150)

NOTICE: Drive it in carefully so that it will not be tilted.

b. Apply small amount of MP grease to the oil seal lip.
73. INSTALL CTR DIFFERENTIAL LOCK SLEEVE





a. Apply hypoid gear oil to a new O-ring.
b. Install the O-ring to the center differential lock sleeve.

NOTICE: Be careful not to twist the O-ring and fit it into the retainer's groove properly.





c. Using SST, install the center differential lock sleeve to the case.
SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)





d. Using a snap ring pliers, install the shaft snap ring.

NOTICE: Check that the snap ring is fitted in the groove of the center differential control coupling assy.





74. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using SST, drive the oil seal into the extension housing to the position shown in the illustration.
SST 09950-60010 (09951-00380, 09951-00580, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Drive it in carefully so that it will not be tilted.

b. Apply small amount of MP grease NO. 2 to the oil seal lip.





75. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR
a. Using SST and a press, install the dust deflector to the extension housing.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
76. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSY





a. Apply sealant 1281 to the extension housing in continuous beaded form of 1.2 mm diameter as shown in the illustration.

NOTICE:
^ Remove any grease from the attaching surfaces.
^ Attach it within 10 min. after application of the sealant.





b. Install the extension housing to the case with the 4 bolts.
Torque: 25.5 Nm (260 kgf-cm, 19 ft. lbs.)
c. Remove the transfer assy from the overhaul attachment.





77. INSTALL TRANSFER & TRANSAXLE SETTING STUD BOLT
a. Install the stud bolts to the parts of the case as shown in the illustration.
Torque: 39.2 Nm (400 kgf-cm, 30 ft. lbs.)

NOTICE: Install the sealant-coated side of the stud bolt to the case.





78. INSTALL TRANSFER CASE STRAIGHT PIN
a. Using a plastic hammer, drive the straight pins into the transfer assy case as shown in the illustration.





79. INSTALL TRANSFER DYNAMIC DAMPER
a. Install the dynamic damper to the extension housing with the 3 bolts.
Torque: 25.5 Nm (260 kgf-cm, 19 ft. lbs.)





80. INSTALL BREATHER OIL DEFLECTOR
a. Install the breather oil deflector to the case cover with the bolt.
Torque: 6.5 Nm (66 kgf-cm, 57 inch lbs.)

NOTICE: Be careful about the direction of the deflector's folding.

81. INSTALL TRANSFER CASE COVER NO. 1





a. Apply sealant 1281 to the case cover in continuous beaded form of 1.2 mm diameter as shown in the illustration.

NOTICE:
^ Remove any grease from the attaching surfaces.
^ Attach it within 10 minutes after application of the sealant.





b. Install the case cover to the case with the 8 bolts.
Torque: 19.6 Nm (200 kgf-cm, 14 ft. lbs.)





82. INSTALL TRANSFER COVER GASKET
a. Install a new gasket to the case.
83. INSTALL TRANSFER ASSY





a. Apply sealant 1281 to the transaxle assy or the transfer assy in continuous beaded form of 1.2 mm diameter as shown in the illustration.

NOTICE:
^ Remove any grease from the attaching surfaces.
^ Install it within 10 minutes after application of 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.





b. After applying sealant, install the intermediate to the transfer assy.





c. Install the transfer assy to the transaxle assy with the 2 bolts and 6 nuts.
Torque: 78.4 Nm (800 kgf-cm, 58 ft. lbs.)

NOTICE:
^ Check that the gasket is installed to the transfer assy before instating 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.

84. INSTALL TRANSFER STIFFENER PLATE RH
a. Install the 2 bolts and right stiffener plate.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)





85. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Install the 6 bolts and rear engine mounting bracket.
Torque:
A: 64 Nm (652 kgf-cm, 47 ft. lbs.)
B: 34 Nm (350 kgf-cm, 25 ft. lbs.)
86. INSTALL FRONT DRIVE SHAFT ASSY RH
87. INSTALL RACK & PINION POWER STEERING GEAR ASSY
88. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (1MZ-FE ENGINE TYPE)
89. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE)





90. INSTALL TRANSFER DRAIN PLUG
a. Install the drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
91. INSTALL TRANSFER CASE NO. 2 PLUG
a. Install the NO. 2 plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
92. INSTALL TRANSFER CASE NO. 1 PLUG
a. Supply oil up to the level 0 - 5 mm down from the lowest end of the plug hole.
Oil quantity: 0.9 L (0.95 US qts., 0.71 Imp. qts.)

NOTICE: When supplying oil, be careful to do it slowly.

b. Install the NO. 1 plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)