DRAIN TRANSFER OIL

REMOVE FRONT PROPELLER SHAFT ASSEMBLY

REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

REMOVE FRONT TRANSFER CASE OIL SEAL

INSTALL FRONT TRANSFER CASE OIL SEAL

INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

INSTALL FRONT PROPELLER SHAFT ASSEMBLY

ADD TRANSFER OIL

CHECK FOR TRANSFER OIL LEAK

except 1GR-FE:

Remove the 2 bolts and transfer dynamic damper.

Remove the 4 bolts and transfer heat insulator.

Remove the 7 bolts and lower transfer case protector.

Remove the filler plug and gasket.

Remove the drain plug and gasket, and drain the transfer oil.

Using SST and a hammer, release the staked part of the nut.

• SST
• 09930-00010(09931-00010,09931-00020)

• NOTICE:

Using SST to hold the companion flange, remove the lock nut.

• SST
• 09330-00021

Using SST, remove the companion flange.

• SST
• 09950-40011(09951-04020,09952-04010,09953-04030,09954-04010,09955-04051,09957-04010,09958-04011)

Remove the O-ring from the companion flange.

Using SST, remove the front transfer case oil seal.

• SST
• 09308-10010
  09950-40011(09957-04010)

• NOTICE:

Apply transfer oil to the spline of the driven sprocket.

Using SST and a hammer, tap in a new front transfer case oil seal.

• SST
• 09613-26010

• NOTICE:

• The front transfer case oil seal should be installed completely.

Install the companion flange onto the drive sprocket.

Using SST to hold the companion flange, install a new O-ring and a new companion flange lock nut.

• SST
• 09330-00021

• Torque:
• 127 N*m{ 1299 kgf*cm, 94 ft.*lbf}

Using a chisel and hammer, stake the companion flange lock nut.

Install a new gasket onto the drain plug and then install the plug.

• Torque:
• 37 N*m{ 377 kgf*cm, 27 ft.*lbf}

Add oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler plug hole.

• NOTICE:

Wait approximately 5 minutes and check that the oil level has not changed.

Install a new gasket onto the filler plug and then install the plug.

• Torque:
• 37 N*m{ 377 kgf*cm, 27 ft.*lbf}

Install the lower transfer case protector with the 7 bolts.

• Torque:
• 14 N*m{ 139 kgf*cm, 10 ft.*lbf}

Install the transfer heat insulator with the 4 bolts.

• Torque:
• 30 N*m{ 306 kgf*cm, 22 ft.*lbf}

except 1GR-FE:

Install the transfer dynamic damper with the 2 bolts.

• Torque:
• 12 N*m{ 122 kgf*cm, 9 ft.*lbf}