Transfer Case Front Oil Seal Replacement

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:

1. Be sure to use SST with the tapered surface facing the shaft.
   
2. Do not grind the tip of SST with a grinder, etc.
   
3. Completely loosen the staked part of the nut when removing it.
   
4. Do not damage the threads of the transfer driven sprocket.
   

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:

1. Be careful not to damage the front transfer case oil seal and front transfer case contact surface.
   
2. Apply grease to the tip of SST center bolt before use.
   

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:

1. Add oil slowly.
   
2. Add oil a little at a time, waiting several minutes between each addition of oil.
   

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}