center differential TOYOTA SEQUOIA 2001 Service Repair Manual

IN04Q±33
IN±40
± INTRODUCTIONTERMS
40 Author: Date:
2005 SEQUOIA (RM1146U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACMActive Control Engine Mount
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CCVCanister Closed Valve
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight

± PREPARATIONSUSPENSION AND AXLE
PP±49
107 Author: Date:
2005 SEQUOIA (RM1146U)
(09710±03051)Bushing ReplacerFront axle
Front suspension
09730±00010Tube RemoverElectronic modulated air suspension
Height control valve
09843±18040Diagnosis Check Wire No.2Tire pressure monitor valve
09922±10010Variable Open WrenchFront suspension
09950±00020Bearing RemoverFront drive shaft
Front differential
Front suspension
Rear differential
09950±30012Puller A Set
(09951±03010)Upper PlateFront differential
Rear differential
(09953±03010)Center BoltFront differential
Rear differential
(09954±03010)ArmFront differential
Rear differential
(09955±03030)Lower Plate 130Front differential
Rear differential
(09956±03020)Adapter 18Front differential
(09956±03050)Adapter 24Rear differential
09950±40011Puller B Set

PP±50
± PREPARATIONSUSPENSION AND AXLE
108 Author: Date:
2005 SEQUOIA (RM1146U)
(09951±04010)Hanger 150Front axle
Front differential
Front suspension
Rear differential
(09951±04020)Hanger 200Front axle
(09952±04010)Slide ArmFront axle
Front differential
Front suspension
Rear differential
(09953±04020)Center Bolt 150Front axle
Front differential
Front suspension
Rear differential
(09954±04010)Arm 25Front axle
Front differential
Front suspension
Rear differential
(09955±04011)Claw No.1Front differential
(09955±04031)Claw No.3Front axle
Front suspension
(09955±04061)Claw No.6Front differential
Rear differential
(09957±04010)AttachmentFront axle
Front differential
Front suspension
Rear differential
(09958±04011)HolderFront axle
Front differential
Front suspension
Rear differential
09950±60010Replacer Set
(09951±00380)Replacer 38Front differential
(09951±00480)Replacer 48Front differential
Rear differential

SS0PY±05
SS±28
± SERVICE SPECIFICATIONSTRANSFER
170 Author: Date:
2005 SEQUOIA (RM1146U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transfer x Transfer adaptor2424518
Engine rear mounting x Transmission6566048
Crossmember x Frame7273053
Engine rear mounting x Crossmember1818513
Heat insulator x Crossmember1616412
Front suspension member bracket x Crossmember3333624
Filler plug x Transfer3737727
Rear propeller shaft x Rear differential8889765
Rear propeller shaft x Transfer8889765
Protector x Transfer1818513
Front propeller shaft x Front differential7475054
Front propeller shaft x Transfer8889765
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Center exhaust pipe4849035
Transfer case cover x Transfer front case1818413
Case plug x Transfer front case18.619014
Front bearing retainer x Transfer front case11.511 98
Front output shaft companion flange lock nut11 81,20387
Oil pump x Front case7.56966 in.´lbf
Oil separator x Front case7.56966 in.´lbf
Transfer shift actuator x Transfer case rear2020415
Front case x Transfer case rear2828621
Shift shaft stopper1919414
Drain and filler plug3737727
Transfer extension housing x Transfer case rear121229
Rear output shaft companion flange lock nut11 81,20387
Gear shift fork2424518

SS1KF±04
± SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS±39
181 Author: Date:
2005 SEQUOIA (RM1146U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
TIRE PRESSURE MONITOR RECEIVER
Tire pressure monitor receiver set bolt7.57666 in.´lbf
TIRE PRESSURE MONITOR VALVE
Tire pressure monitor valve set nut4.04135 in.´lbf
FRONT AXLE
Hub nut11 01,15083
Tie rod end lock nut5556041
Steering knuckle x Brake caliper8082059
Steering knuckle x Dust cover1231,25090
Drive shaft lock nut1818513
Upper suspension arm x Upper ball joint2352,400173
Brake line clamp x Steering knuckle1051,10077
ABS speed sensor x Steering knuckle2828521
ABS speed sensor wire harness clamp x Steering knuckle8.08271 in.´lbf
ABS speed sensor wire harness clamp x Upper suspension arm8.08271 in.´lbf
FRONT DIFFERENTIAL
Drive pinion x companion flangeSee page SA±43
Differential front mounting cushion x Chassis frame1371,400101
Differential rear mounting cushion x Chassis frame8789064
Differential front mounting cushion x Differential1571,60011 6
Differential rear mounting cushion x Differential1081,10080
Ring gear x Differential case9798571
Differential carrier x Differential tube7880058
Differential carrier x Side bearing retainer6970051
Differential x Front propeller shaft7475054
A.D.D. clutch case x Differential7880058
A.D.D. clutch case x Differential tube7880058
A.D.D. actuator x A.D.D. clutch case2121015
Tube with wire harness assembly clamp x Differential carrier131309
Drain plug6566048
Filler plug3940029
FRONT SUSPENSION
Suspension support x Chassis frame6465047
Piston rod x Suspension support2525018
Lower suspension arm x Shock absorber1351,400100
Upper suspension arm x Chassis frame981,00072
Lower suspension arm x Chassis frame1301,32596
Lower suspension arm x Lower ball joint1591,62111 7
Power steering gear Left side nut
Center bolt
Right side bolt and nut130
165
1651,350
1,700
1,70096
122
122
Tie rod end x Lower ball joint9193067
No. 1, No. 2 spring bumper31 (23)315 (235)23 (17)
Lower suspension arm x Stabilizer bar link6970051

± DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
DI±977
1171 Author: Date:
2005 SEQUOIA (RM1146U)
DTC C1340 / 47 Center DIFF. Lock Circuit Malfunction
CIRCUIT DESCRIPTION
This circuit sends the signal to the ECU by detecting that the transfer center differential is in the ºLOCKº posi-
tion.
DTC No.DTC Detecting ConditionTrouble Area
C1340 / 47Center diff. lock position switch signal does not change

Center diff. lock position switch

Center diff. lock position switch circuit

Center diff. lock Indicator light circuit

Translate ECU
DIDMD±01

DI±980
± DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
1174 Author: Date:
2005 SEQUOIA (RM1146U)
INSPECTION PROCEDURE
1 Check center differential lock operation (See page TR±39).
OK:
Center differential lock operation is norm.
NG Repair or replace one±touch 2±4 selector sys-
tem.
OK
2 Check operation of the center differential lock indicator light.
PREPARATION:
(a) Turn the ignition switch to the ON position.
(b) Set the transfer to the L4 position.
CHECK:
Check that pressing the center differential lock switch locks the differential and turns the lock indicator on.
OK:
Indicator light: ON/OFF or OFF/ON
HINT:
When the center differential cannot be shifted to LOCK smoothly, the center differential lock indicator light
will blink.
NG Repair or replace center differential lock indica-
tor light circuit.
OK
3 Check that the 4WD ECU connectors are securely connected to the 4WD ECU.
NO Connect the connector to the 4WD ECU.
YES

TR04H±04
TR±2
± TRANSFERTROUBLESHOOTING
2940 Author: Date:
2005 SEQUOIA (RM1146U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help find the cause of the problem. The numbers indicate the priority of the likely cause
of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspected AreaSee page
Noise
1. Oil (Level low)
2. Oil (Wrong)
3. Transfer faultyTR±5
TR±5
TR±7
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O±ring (Worn or damaged)TR±5
TR±7
TR±16
TR±7
Tight corner brakingCenter differential or transfer faultyTR±7
Shift from 2WD (H) to 4WD (H) impossible
1. 4WD fuse
2. Wire harness
3. Vehicle speed sensor
4. 2WD/4HI switch
5. 4WD indicator light
6. Actuator assembly
7. A.D.D. control system
8. 4WD control ECU
9. Transfer assembly±
±
BE±55
TR±39
TR±39
TR±39
SA±61
TR±39
TR±3
Shift from 2WD (H) to 4WD (L4) impossible
1. 4LO switch
2. Wire harness
3. 4WD control ECUTR±39
±
TR±39
Shift from 4WD (H) to 4WD (L4) impossible
1. 4LO switch
2. Wire harness
3. 4WD control ECUTR±9
±
TR±39
Shift from 4WD (H) to 2WD (H) impossible
1. 4WD fuse
2. Wire harness
3. 4WD indicator light
4. Actuator assembly
5. A.D.D. control system
6. 4WD control ECU
7. Transfer assembly±
±
TR±39
TR±39
SA±61
TR±39
TR±3
Shift from 4WD (L4) to 2WD (H) impossible
1. 2WD/4HI switch
2. Wire harness
3. 4WD control ECUTR±39
±
TR±39
Shift from 4WD (L4) to 4WD (H) impossible
1. 2WD/4HI switch
2. Wire harness
3. 4WD control ECUTR±39
±
TR±39

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.