Toyota Land Cruiser

2. Press in the new bearing with SST. SST [09608-20011] No.2

Gear

Inspect the teeth, thrust faces and inside diameter surfaces for wear or damage.

Measure the on clearance.

High & low speed output gear: STD 0.035-0.081 mm

Bearing

Inspect for wear or damage.

Sleeve & Fork

Check the clearance between the sleeves and the shift forks.

Clearance: 0.1-0.4 mm

Idler Gear

Inspect for wear or damage

Fig. 4-43

Replace The Transfer Rear Oil Seal

1. Remove the oil seal with SST. |- SST [09308-10010]

2. Install the oil seal to the correct depth with SST.

SST [09316-60010] Oil seal depth:

0 Replace The Transmission Rear Oil Seal

1. Remove the oil seal with driver.

2. Install the oil seal to the correct depth with SST.

Oil Seal Depth:

4-14

TRANSFER - Transfer (H41 & H42)

High & Low Gear Select Lever Oil Seal

1. Remove the oil seal by prying it with a screwdriver.

2. Install the oil seal to the correct depth with SST.

SST [09608-20011] No.2

Oil Seal depth: 0-1 mm

ASSEMBLY

1. Assemble the parts in the numerical order shown in the figure.

1.

Rear Output Shaft

2.

Clutch Sleeve

3.

Low Speed Gear

4.

Bearing

5.

High Speed Gear

6.

Bearing

7.

Clutch Hub

8.

Coat MP grease on the shaft and install the high and low gears.

Install a bearing with a press and SST. SST [09316-60010]

Coat MP grease on the shaft and install the high and low gears.

Install a bearing with a press and SST. SST [09316-60010]

0 Install a bearing with a press and SST. SST [09316-60010]

Fig. 4-50

Select a snap ring of a thickness that will allow minimum axial play. Axial play:

Mark

Thickness mm (in.)

90520-33107

2.30 - 2.35 (0.0906 - 0.0925)

90520-331 10

2.60 - 2.65 (0.1024 - 0.1043)

Install the snap ring with SST. SST [09905-00012]

0 Apply gear oil on the assembled parts, gears, bearings and shaft.

2. Assemble the parts in the numerical order shown in the figure.

1kz Transfer Case

Fig 4-58

Fig 4-58

Front Output SHaft 13.

Ball & Spacer 14.

Gasket & Intermediate Plate 15.

Transmission Output Gear 16.

Spacer & PTO Drive Gear Bearing

Washer & Lock Nut Front Drive Shift Fork, Shaft & Sleeve

Bearing Retainer Thrust Washer Bearing, Spacer & Idler Gear

Press in the shaft with SST. SST [09316-60010]

Coat MP grease on the oil seal.

Fit the collar groove securely over the locking ball.

Coat MP grease on the oil seal.

1. Apply liquid sealer to the bolts.

2. Install the intermediate plate mounting bolts in the position shown in the figure.

Tightening torque:

Install the gear with SST. SST [09309-36032]

Install the shift fork, shaft and clutch hub sleeve.

Drive in the slotted spring pin.

Temporarily tighten the lock nut.

Drive in the bearing with SST. SST [09316-60010]

Drive in the bearing with SST. SST [09316-60010]

Temporarily tighten the lock nut.

Drive in the slotted spring pin.

Install the shift fork, shaft and clutch hub sleeve.

B Install the outer races with SST. SST [09316-60010]

Install the bearing retainer by tapping with the plastic hammer.

Drive in the slotted spring pin.

Install the shift fork, shaft and output shaft together.

Fig. 4-68

Do not completly insert the idler gear shaft — -Note-

Do not install the rear side O ring on the shaft.

3. Assemble the parts in the numerical-order shown in the figure.

4-78

4-85

19. Spacer & Speedometer Drive Gear 25.

20. Gasket & Transfer Case 26.

21. 0 Ring & Lock Plate 27. 22 Bearing Retainer 28. 23. Companion Flange 29. 24 Companion Flange 30.

Cover Cover

Speedometer Driven Gear Locking Ball & Spring Locking Ball & Spring Shift Lever

Stick the thrust washer to the case with MP grease.

0When installing the case, turn the select lever counterclockwise and engage the lever tip to the shaft groove.

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