Transfer Case Oil Seal Replacement

Remove the 4 bolts and protector.

Remove the front propeller shaft (Toyota Fortuner RM0000010QG009X_01_0001.html).

Using a chisel and hammer, loosen the staked part of the lock nut.

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)

Using SST, tap out the oil seal.

SST

09308-00010

NOTICE:

Be careful not to damage the oil seal and case front contact surface.

Coat the lip of a new oil seal with MP grease.

Using SST and a hammer, tap in the oil seal until its surface is flush with the case upper surface.

SST

09316-60011(09316-00011)

Apply gear oil to the connecting areas of the companion flange and driven sprocket.

Install the companion flange to the driven sprocket.

Using SST to hold the companion flange, install a new lock nut.

SST

09330-00021
09950-40011(09951-04020,09952-04010,09953-04030,09955-04051,09957-04010,09958-04011)

Torque:

118 N*m{1,203 kgf*cm, 87 ft.*lbf}

Using a chisel and hammer, stake the lock nut to the driven sprocket.

NOTICE:

1. Thoroughly stake the shaft to the lock nut's groove.
   
2. Be careful not to damage parts around the lock nut.
   
3. Do not apply excessive force to the shaft.
   

Install the front propeller shaft (Toyota Fortuner RM000000ZYG008X_01_0001.html).

Install the protector with the 4 bolts.

Torque:

18 N*m{183 kgf*cm, 13 ft.*lbf}

Remove the case plug (for filler) and gasket.

Pour oil so that the oil level is between 0 to 5.0 mm (0 to 0.20 in.) from the bottom lip of the case plug (for filler) hole.

NOTICE:

1. When adding oil, pour it 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 and the case plug (for filler).

Torque:

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