Transfer Unit: Installation

WARNING: This page is about a different variant/trim than selected.

RAISE VEHICLE
INSTALL TRANSFER
Raise the transfer and install it to the transfer adaptor with the 8 transfer mounting bolts.
1. Torque: 24 N.m (240 kgf.cm, 17 ft.lbf)
NOTE: Take care not to damage the lip of the transfer adaptor rear oil seal with the transfer input shaft.
CONNECT VEHICLE SPEED SENSOR, NEUTRAL POSITION SWITCH, L4 POSITION SWITCH, MOTOR ACTUATOR, NO. 1 AND NO. 2 4WD POSITION SWITCH CONNECTORS.

Fig 1: Installing Transfer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE REAR MOUNTING
Install the engine rear mounting to the transfer adaptor with the 4 bolts.
1. Torque: 65 N.m (650 kgf.cm, 48 ft.lbf)
INSTALL CROSS MEMBER
1. Install the cross member with the 4 bolts and nuts.
  1. Torque: 72 N.m (740 kgf.cm, 53 ft.lbf)
2. Install the 4 set bolts of the engine rear mounting.
  1. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
3. Remove the transmission jacks.
INSTALL FRONT AND REAR PROPELLER SHAFTS (See INSTALLATION )
INSTALL LH AND RH FRONT EXHAUST PIPES (See INSTALLATION )

Fig 2: Installing Engine Rear Mounting
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FILL TRANSFER OIL
1. Oil grade: API GL-4 or GL-5
2. Viscosity: SAE 75W-90
3. Capacity: 1.2 liters (1.3 US gts, 1.1 Imp.gts)
4. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
INSTALL PROTECTOR
Install the protector with the 4 bolts.
1. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
Fig 3: Locating Filler & Drain Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER SHIFT LEVER
1. Lower the vehicle.
2. Apply MP grease to the tip of the transfer shift lever.
3. Pressing down on the transfer shift lever cap, and using pliers, install the snap ring.
  
  Fig 4: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the shift lever boot with the 4 bolts.
  1. Torque: 7.0 N.m (70 kgf.cm, 61 in..lbf)
5. Install the upper console panel.
6. Install the transfer shift lever knob.
DO ROAD TEST
Check for abnormal noise and smooth shifting.

Fig 5: Locating Shift Lever Boot Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002