TOYOTA SEQUOIA 2001 Service Repair Manual

TR00G±08
F19254
F19255
Steel Bar
SST
F19302
SST
F19303
± TRANSFERDRIVEN SPROCKET
TR±25
2963 Author: Date:
2005 SEQUOIA (RM1146U)
REPLACEMENT
1. REMOVE FRONT BEARING
Using a press, remove the front bearing.
2. REMOVE REAR BEARING
Using SST, a press and steel bar, remove the rear bearing.
SST 09555±55010
3. INSTALL REAR BEARING
Using SST and a press, install a new rear bearing.
SST 09316±60011 (09316±00031)
4. INSTALL FRONT BEARING
Using a press, install a new front bearing.

TR083±03
F19236
Output Shaft Rear
Radial Ball Bearing
Output Shaft Spacer No. 1
Output Shaft Front
Needle Roller Bearing
Synchronizer Ring Set
Front Drive Clutch Sleeve

Non±reusable partCenter Differential Case
Ball
Snap Ring
Output Shaft Spacer No. 2Drive Sprocket
Drive Sprocket Bear-
ing
Output Shaft
Plate Washer
Output Shaft Rear Output Shaft
Plate Washer
Synchromesh Shifting Key Spring
Synchromesh Shifting Key
Clutch Hub
TR±26
± TRANSFERREAR OUTPUT SHAFT
2964 Author: Date:
2005 SEQUOIA (RM1146U)
REAR OUTPUT SHAFT
COMPONENTS

TR0DH±01
F19276
F19277
F19278
F19279
± TRANSFERREAR OUTPUT SHAFT
TR±27
2965 Author: Date:
2005 SEQUOIA (RM1146U)
DISASSEMBLY
1. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of the drive
sprocket.
Standard clearance:
0.15 to 0.24 mm (0.0059 to 0.0094 in.)
Maximum clearance:
0.24 mm (0.0094 in.)
If the clearance exceeds the maximum, replace the drive
sprocket.
2. INSPECT DRIVE SPROCKET RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of the drive
sprocket.
Standard clearance:
0.01 to 0.06 mm (0.0004 to 0.0024 in.)
Maximum clearance:
0.06 mm (0.0024 in.)
If the clearance exceeds the maximum, replace the drive
sprocket, output shaft rear or needle roller bearing.
3. REMOVE CENTER DIFFERENTIAL CASE
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the output shaft spacer No. 2 and ball.
(c) Remove the center differential case.
4. REMOVE CLUTCH HUB
Remove the clutch hub, output shaft front needle roller bearing
and output shaft plate washer.

F19280
F19281
F19282
SST
F19283
TR±28
± TRANSFERREAR OUTPUT SHAFT
2966 Author: Date:
2005 SEQUOIA (RM1146U)
5. REMOVE FRONT DRIVE CLUTCH SLEEVE
(a) Using a screwdriver, remove the 2 shifting key springs.
(b) Remove the 3 shifting keys.
(c) Remove the front drive clutch sleeve.
6. REMOVE SYNCHRONIZER RING SET
7. REMOVE DRIVE SPROCKET
(a) Using SST and a press, remove the output shaft rear ra-
dial ball bearing.
SST 09555±55010
(b) Remove the output shaft spacer No. 1 and drive sprocket.
(c) Remove the output shaft plate washer and drive sprocket
bearing.

TR0DI±01
F19284
A B C D
F19286
± TRANSFERREAR OUTPUT SHAFT
TR±29
2967 Author: Date:
2005 SEQUOIA (RM1146U)
INSPECTION
1. INSPECT OUTPUT SHAFT REAR
Using a micrometer, measure the outer diameter of the output
shaft rear journal surface.
Standard diameter:
Part A: 27.98 to 27.99 mm (1.1016 to 1.1020 in.)
Part B: 31.98 to 32.00 mm (1.2591 to 1.2598 in.)
Part C: 34.98 to 35.00 mm (1.3772 to 1.3780 in.)
Part D: 36.98 to 37.00 mm (1.4559 to 1.4567 in.)
Minimum diameter:
Part A: 27.98 mm (1.1016 in.)
Part B: 31.98 mm (1.2591 in.)
Part C: 34.98 mm (1.3772 in.)
Part D: 36.98 mm (1.4559 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft rear.
2. INSPECT FRONT DRIVE CLUTCH SLEEVE AND
GEAR SHIFT FORK NO. 1 CLEARANCE
(a) Using vernier calipers, measure the thickness of the gear
shift fork No. 1 claw.
Thickness: 10 mm (0.3937 in.)
(b) Using vernier calipers, measure the width of the groove
of the front drive clutch sleeve.
Width: 10.5 mm (0.4134 in.)
(c) Calculate the clearance between the front drive clutch
sleeve and gear shift fork No. 1.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the front drive
clutch sleeve or gear shift fork No. 1.

F19285
F19288
F19287
TR±30
± TRANSFERREAR OUTPUT SHAFT
2968 Author: Date:
2005 SEQUOIA (RM1146U)
3. INSPECT HIGH AND LOW CLUTCH SLEEVE AND
GEAR SHIFT FORK NO. 2 CLEARANCE
(a) Using vernier calipers, measure the thickness of the gear
shift fork No. 2 claw.
Thickness: 10 mm (0.3937 in.)
(b) Using vernier calipers, measure the width of the groove
of the high and low clutch sleeve.
Width: 10.5 mm (0.4134 in.)
(c) Calculate the clearance between the high and low clutch
sleeve and gear shift fork No. 1.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the high and
low clutch sleeve or gear shift fork No. 2.
4. INSPECT CENTER DIFFERENTIAL CASE AND FRONT
DRIVE CLUTCH SLEEVE
(a) Check that the tip of the spline gear of the front drive
clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center differen-
tial case and check that the front drive clutch sleeve
moves smoothly.
5. INSPECT CENTER DIFFERENTIAL CASE AND HIGH
AND LOW CLUTCH SLEEVE
(a) Check that the tip of the spline gear of the front drive
clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center differen-
tial case and check that the front drive clutch sleeve
moves smoothly.

TR0DJ±01
F19283
F19751
SST
Groove
F19281
F19293
F19294
± TRANSFERREAR OUTPUT SHAFT
TR±31
2969 Author: Date:
2005 SEQUOIA (RM1146U)
REASSEMBLY
1. INSTALL DRIVE SPROCKET
(a) Install the output shaft plate washer and drive sprocket
bearing to the output shaft rear.
(b) Install the drive sprocket and output shaft spacer No. 1 to
the output shaft rear.
(c) Using SST and a press, install a new output shaft rear ra-
dial ball bearing.
SST 09316±60011 (09316±00011, 09316±00071)
NOTICE:
Install the output shaft rear radial ball bearing so that the
groove for the snap ring does not face the drive sprocket.
2. INSTALL SYNCHRONIZER RING SET
3. INSTALL FRONT DRIVE CLUTCH SLEEVE
4. INSTALL CLUTCH HUB
(a) Install the 3 shifting keys to the clutch hub.
(b) Install the 2 shifting key springs to the clutch hub.
NOTICE:
Position the shifting key springs so that their end gaps are
not aligned.

F19279
F19278
F19276
F19277
TR±32
± TRANSFERREAR OUTPUT SHAFT
2970 Author: Date:
2005 SEQUOIA (RM1146U)
(c) Install the output shaft plate washer and output shaft front
needle roller bearing to the output shaft rear.
(d) Install the clutch hub to the output shaft rear.
5. INSTALL CENTER DIFFERENTIAL CASE
(a) Install the center differential case to the output shaft rear.
(b) Install the ball and output shaft spacer No. 2 to the center
differential case.
(c) Using a snap ring expander, install the snap ring.
6. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of the drive
sprocket.
Standard clearance:
0.15 to 0.24 mm (0.0059 to 0.0094 in.)
Maximum clearance:
0.24 mm (0.0094 in.)
If the clearance exceeds the maximum, replace the drive
sprocket.
7. INSPECT DRIVE SPROCKET RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of the drive
sprocket.
Standard clearance:
0.01 to 0.06 mm (0.0004 to 0.0024 in.)
Maximum clearance:
0.06 mm (0.0024 in.)
If the clearance exceeds the maximum, replace the drive
sprocket, output shaft rear or needle roller bearing.

TR04O±04
F19233

Oil Seal Ring
Input Shaft

Non±reusable part
± TRANSFERINPUT SHAFT
TR±33
2971 Author: Date:
2005 SEQUOIA (RM1146U)
INPUT SHAFT
COMPONENTS

TR0DK±01
F19268
F19269
F19270
F19298
TR±34
± TRANSFERINPUT SHAFT
2972 Author: Date:
2005 SEQUOIA (RM1146U)
INSPECTION
1. REMOVE 2 OIL SEAL RINGS
2. INSPECT INPUT SHAFT
(a) Using a micrometer, measure the outer diameter of the in-
put shaft journal surface.
Minimum diameter: 47.59 mm (1.8736 in.)
If the outer diameter is less than the minimum, replace the input
shaft.
(b) Using a dial indicator, measure the inside diameter of the
input shaft bushing.
Maximum diameter: 48.14 mm (1.8953 in.)
If the inside diameter exceeds the maximum, replace the input
shaft.
3. INSTALL 2 OIL SEAL RINGS
HINT:

Apply gear oil to the oil seal ring.

Engage securely to eliminate clearance as shown in the
illustration.