| Last Modified: 4-30-2014 | 6.6 A | Doc ID: RM0000018CZ001X |
| Model Year: 2006 | Model: LX470 | Prod Date Range: [05/2005 - ] |
| Title: HF2A TRANSFER: TRANSFER ASSEMBLY: REASSEMBLY; 2006 MY LX470 [05/2005 - ] | ||
REASSEMBLY
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1. CHECK NO. 2 SHIFT FORK AND CLUTCH SLEEVE CLEARANCE (a) Using a feeler gauge, measure the clearance between the No. 2 shift fork and clutch sleeve. Standard clearance: 0.10 to 0.40 mm (0.0039 to 0.0157 in.) Maximum clearance: 0.40 mm (0.0157 in.) If the clearance is greater than the maximum, replace the No. 2 shift fork or clutch sleeve. |
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2. INSTALL BEARING RACE (OUTPUT SHAFT) (a) Using SST and a press, press in the bearing race to the front case. SST: 09316-60011 09316-00011 09316-00031 SST: 09950-60020 09951-00890 |
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3. INSTALL BEARING RACE (IDLER GEAR) (a) Using SST and a press, press in the bearing race to the front case. SST: 09316-60011 09316-00031 09316-00011 SST: 09950-60020 09951-00890 |
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4. INSTALL OIL RECEIVER (a) Install the oil receiver to the front case with the bolt. Torque: 12 N·m {120 kgf·cm, 9ft·lbf} |
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5. INSTALL INPUT SHAFT OIL SEAL (a) Apply MP grease to the lip of a new oil seal. (b) Using SST and a hammer, tap in the oil seal to the front case. SST: 09316-60011 09316-00011 09316-00031 |
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6. INSTALL INNER SHIFT LEVER OIL SEAL (a) Apply MP grease to the lip of a new oil seal. (b) Using SST and a hammer, tap in the oil seal to the front case. SST: 09950-60010 09951-00270 SST: 09950-70010 09951-07150 |
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7. INSTALL OUTER SHIFT LEVER AND INNER SHIFT LEVER (a) Install the inner shift lever, washer and outer shift lever to the front case. (b) Using a pin punch, hammer and socket wrench, tap in the lever lock pin. (c) Install the washer and nut to the outer shift lever. Torque: 12 N·m {120 kgf·cm, 9ft·lbf} |
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8. ASSEMBLE NO. 1 SHIFT FORK AND NO. 1 SHIFT FORK SHAFT (a) Assemble the No. 1 shift fork and No. 1 shift fork shaft. (b) Using a pin punch and hammer, tap in the slotted spring pin. |
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9. INSTALL IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, NO. 1 SHIFT FORK AND NO. 1 SHIFT FORK SHAFT NOTICE: Set the shift inner lever into the fork head part of the No. 1 shift fork securely. |
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10. INSTALL INPUT SHAFT SUB-ASSEMBLY
11. INSTALL BEARING RACE
(a) Install the 2 bearing races to the rear case.
12. ASSEMBLE FRONT CASE AND REAR CASE
(a) Apply seal packing to the front case.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
(b) Assemble the front case and rear case.
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(c) Apply liquid sealer to the "A" bolt threads. Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent |
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(d) Install the 8 bolts.
Torque:
37 N·m {380 kgf·cm, 27ft·lbf}
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(e) Using a snap ring expander, install the snap ring to the rear case. |
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13. INSTALL CASE COVER
(a) Apply seal packing to the rear case.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
(b) Install the case cover.
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(c) Apply liquid sealer to the bolt threads. Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent |
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(d) Install the 5 bolts.
Torque:
37 N·m {380 kgf·cm, 27ft·lbf}
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14. INSTALL OIL STRAINER ASSEMBLY (a) Install the oil strainer to the rear case with the 2 bolts. Torque: 4.9 N·m {50 kgf·cm, 43in·lbf} |
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15. SELECT ADJUSTING SHIM (REAR IDLER GEAR TAPER ROLLER BEARING)
(a) Using a vernier caliper, measure dimension "A".
(b) Lightly hold down the outer bearing race in the thrust direction to eliminate any looseness before making the measurement.
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(c) Using a steel straightedge and feeler gauge, measure the clearance of dimension "B". |
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(d) Calculate the required thickness of the adjusting shim.
Standard thickness:
Dimension "A" + Dimension "B" + (0.022 to 0.049 mm, (0.0009 to 0.0019 in.))
(e) From the following table, select a shim so that its thickness is within the range of the calculation.
Standard snap ring thickness:
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Mark |
Thickness mm (in.) |
Mark |
Thickness mm (in.) |
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2 |
0.30 (0.0118) |
8 |
3.20 (0.1260) |
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3 |
0.45 (0.0177) |
9 |
3.40 (0.1339) |
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4 |
2.40 (0.0945) |
10 |
3.60 (0.1417) |
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5 |
2.60 (0.1024) |
11 |
3.80 (0.1496) |
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6 |
2.80 (0.1102) |
12 |
4.00 (0.1575) |
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7 |
3.00 (0.1181) |
13 |
0.55 (0.0216) |
16. SELECT ADJUSTING SHIM (OUTPUT SHAFT TAPER ROLLER BEARING)
(a) Using a steel straightedge and feeler gauge, measure the clearance of dimension "C".
(b) Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
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(c) Using a steel straightedge and vernier caliper with depth gauge, measure dimension "D". |
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(d) Dimension "D" is the straightedge thickness (Dimension "F") subtracted from dimension "E" in the illustration.
Dimension "D":
Dimension "E" - Dimension "F"
(e) Using a steel straightedge and vernier caliper with depth gauge, measure dimension "G".
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(f) Dimension "G" is the straightedge thickness (Dimension "F") subtracted from Dimension "H". Dimension "G": Dimension "H" - Dimension "F" |
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(g) Calculate the require thickness of the adjusting shim.
Thickness:
Dimension "G" - (Dimension "D" - Dimension "C") + (0.014 to 0.039 mm, (0.0006 to 0.0015 in.))
(h) From the following table, select a shim so that its thickness is within the range of the calculation.
Standard snap ring thickness:
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Mark |
Thickness mm (in.) |
Mark |
Thickness mm (in.) |
|---|---|---|---|
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B |
0.30 (0.0118) |
H |
1.80 (0.0709) |
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C |
0.45 (0.0177) |
J |
2.00 (0.0787) |
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D |
1.00 (0.0394) |
K |
2.20 (0.0866) |
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E |
1.020 (0.0472) |
L |
2.40 (0.0945) |
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F |
1.40 (0.0551) |
M |
2.60 (0.1024) |
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G |
1.60 (0.0630) |
N |
0.56 (0.0216) |
17. INSTALL REAR TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
(a) Apply seal packing to the extension housing.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
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(b) Install the extension housing with the 9 bolts. Torque: 37 N·m {380 kgf·cm, 27ft·lbf} |
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18. ASSEMBLE NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK (a) Install the No. 2 shift fork to the No. 2 shift fork shaft. (b) Install the 3 snap rings to the No. 2 shift fork shaft. |
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19. INSTALL CLUTCH SLEEVE WITH NO. 2 SHIFT FORK SHAFT AND NO. 2 SIFT FORK
HINT:
Make sure to install the clutch sleeve in the correct direction.
20. INSTALL FRONT TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
(a) Apply seal packing to the extension housing.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
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(b) Install the extension housing with the 6 bolts. Torque: 37 N·m {380 kgf·cm, 27ft·lbf} HINT: Set the clutch sleeve in differential lock condition. |
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21. INSTALL TRANSFER INDICATOR SWITCH
(a) Install the 3 indicator switches with 3 new gaskets.
Torque:
37 N·m {380 kgf·cm, 27ft·lbf}
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22. INSTALL BALL |
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23. INSTALL SPRING
24. INSTALL SCREW PLUG
(a) Apply liquid sealer to the screw plug threads.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(b) Using a T40 "torx" socket, install the screw plug.
Torque:
19 N·m {190 kgf·cm, 14ft·lbf}
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25. INSTALL OUTPUT GEAR (a) Apply gear oil to the output gear. (b) Install the output gear to the front case. NOTICE: Do not turn the output gear. |
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26. INSTALL MOTOR ACTUATOR
(a) Apply seal packing to the motor actuator.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
HINT:
Set the motor actuator in differential lock condition.
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(b) Install the motor actuator with the 4 bolts. Torque: 18 N·m {185 kgf·cm, 13ft·lbf} |
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27. INSTALL VEHICLE SPEED SENSOR DRIVEN GEAR
(a) Install the driven gear with the bolt.
Torque:
11 N·m {115 kgf·cm, 8ft·lbf}
28. INSTALL BREATHER HOSE
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