TOYOTA SIENNA 2007 Service Repair Manual

TRANSFER – TRANSFER UNITTF–21
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INSPECTION
1. INSPECT PRELOAD
(a) Using SST(s) and a torque wrench, check the initial
torque within the backlash range.
SST 09326-20011
Torque: 0.9 to 1.4 N*m (9 to 14 kgf*cm, 8.0 to
12.4 in.*lbf)
HINT:
Use a torque wrench with a fulcrum length of 160
mm (6.30 in.).
(b) Using SST(s) and a torque wrench, check the initial
torque while the driven pinion is in contact with the
ring gear face.
SST 09326-20011
Torque: Preload
+0.15 to 0.30 N*m (+1.6 to 3.1 kgf*cm,
+1.3 to 2.7 in.*lbf)
HINT:
Use a torque wrench with a fulcrum length of 160
mm (6.30 in.).
2. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Set the dial gauge perpendicular to the tooth face of
the ring gear, fix the driven pinion and inspect the
backlash while moving the gear.
Backlash:
0.10 to 0.15 mm (0.0039 to 0.0059 in.)
NOTICE:
Inspect it at 3 points or more on the gear's
periphery.
3. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Apply red lead primer thinly and uniformly to both
faces of the ring gear and rotate several times.
NOTICE:
Inspect the tooth contact on the ring gear at 4
places or more.
4. INSPECT RUNOUT OF TRANSFER RING GEAR
MOUNTING CASE
(a) Using a dial gauge check the transfer ring gear
mounting case runout.
Maximum runout:
0.03 mm (0.0012 in.)
C083635E05
C050309
C050346
C099000

TF–22TRANSFER – TRANSFER UNIT
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REASSEMBLY
1. INSTALL TRANSFER DRIVEN PINION REAR
BEARING
(a) Using SST(s) and a press, install the transfer driven
pinion rear bearing outer race to the transfer case.
SST 09950-60010 (09951-00620), 09950-70010
(09951-07150)
NOTICE:
Place something like wood blocks under the
case to keep its level.
2. INSTALL TRANSFER OUTPUT WASHER
(a) Install the transfer output washer to the transfer
case.
HINT:
Reuse the washer.
3. INSTALL TRANSFER DRIVEN PINION FRONT
BEARING
(a) Install the transfer driven pinion front bearing outer
race to the transfer case with SST(s), bolt and nut.
SST 09950-60020 (09951-00750, 09951-00770,
09951-00810), 09316-60011 (09316-00061)
4. INSTALL RING GEAR MOUNTING CASE PLATE
WA S HE R
(a) Install the ring gear mounting case plate washer to
the transfer case.
HINT:
Reuse the washer.
5. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Using SST(s) and a press, install the center
differential case tapered roller bearing LH outer race
to the transfer case.
SST 09950-70010 (09951-07200), 09316-60011
(09316-00021)
6. INSTALL TRANSFER DRIVEN PINION FRONT
BEARING
(a) Using SST(s) and a press, install the transfer driven
pinion front bearing inner race to the driven pinion.
C082982E01
C083647E01
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TRANSFER – TRANSFER UNITTF–23
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7. INSTALL DRIVEN PINION
(a) Install the driven pinion to the transfer case.
(b) Install a new transfer pinion bearing spacer and
anew transfer driven pinion rear bearing inner race
to the driven pinion.
(c) Using SST(s), tighten a new transfer gear nut (at a
standard torque.)
SST 09326-20011, 09556-16030
Torque: 277 to 378 N*m (2,820 to 3,855 kgf*cm,
204 to 279 ft.*lbf)
NOTICE:
Do not stake the transfer gear nut.
HINT:
Use a torque wrench with a fulcrum length of 750
mm (29.53 in.)
8. INSPECT AND ADJUST DRIVEN PINION PRELOAD
(a) Using SST(s) and a torque wrench, measure thee
initial torque of the driven pinion.
SST 09326-20011, 09556-16030
Torque: New bearing
1.1 to 1.6 N*m (10 to 16 kgf*cm, 9.7 to
14.2 in.*lbf)
Used bearing
0.9 to 1.4 N*m (9 to 14 kgf*cm, 8.0 to
12.4 in.*lbf)
HINT:
Use a torque wrench with a fulcrum length of 160
mm (6.30in.)
NOTICE:
Measure preload after rotating the bearing both
clockwise and counterclockwise to make it fit.
(b) If the preload is too large, replace the transfer pinion
bearing spacer with a new one.
(c) If the preload is too small, repeatedly adjust the
preload by tightening the transfer gear nut 5 to 10
degrees at a time until the standard value is
obtained.
C050338
C050339
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TF–24TRANSFER – TRANSFER UNIT
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(d) If the preload is insufficient, even though the
tightening torque of the transfer gear nut exceeds
the maximum of the standard value., loosen the
transfer gear nut and apply gear oil SAE 90 (GL-5)
to the transfer gear nut and the screw thread and
the base of driven pinion. And then repeat the
preceding operation . If the tightening torque is
bearing spacer with anew one and adjust it.
Torque: 378 N*m (3.855 kgf*cm, 279 ft.*lbf)
9. INSTALL RING GEAR
(a) Heat the ring gear in boiling water from 90 to 100
C
(194 to 212
F).
(b) Completely remove grease and moisture on the
contact surfaces of the ring gear and the transfer
ring gear mounting case.
(c) Align the matchmarks on the ring gear and transfer
ring gear mounting case and quickly assemble
them.
(d) Tighten the 12 bolts.
Torque: 78 N*m (790 kgf*cm, 57 ft.*lbf)
NOTICE:
• Tighten the bolts in diagonal order in splitting
several times.
• After the ring gear has well cooled down, fully
tighten the bolts.
• Make the bolt heads in order to check if they
are retightened or not.
10. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Using SST(s) and a press, install the inner race of
the center differential case tapered roller bearing to
the transfer ring gear mounting case.
SST 09506-35010, 09950-60010 (09951-00430),
09223-00010
NOTICE:
When replacing the inner race, replace it
together with the outer race.
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TRANSFER – TRANSFER UNITTF–25
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11. INSTALL TRANSFER RING GEAR MOUNTING CASE
(a) Install the transfer ring gear mounting case to the
transfer case.
NOTICE:
Damage to the spline, the bearing's rotating
surface and gear face may cause a decrease in
their strength. Care should be taken when
installing them.
12. INSTALL NO. 2 TRANSFER RING GEAR MOUNTING
CASE WASHER
(a) Install the No. 2 transfer ring gear mounting case
washer to the transfer RH bearing retainer sub-
assembly.
HINT:
Reuse the washer.
13. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Using SST(s) and a press, install the center
differential case tapered roller bearing RH outer
race to the transfer RH bearing retainer sub-
assembly.
SST 09950-60010 (09951-00620), 09950-70010
(09951-07150)
14. INSTALL TRANSFER RH BEARING RETAINER SUB-
ASSEMBLY
(a) Place the transfer with the surface where the
transfer RH bearing retainer sub-assembly is facing
up.
(b) Align the centers of the transfer ring gear mounting
case and the transfer case.
(c) Insert SST into the transfer RH bearing retainer sub-
assembly.
SST 09387-00090
C067673
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TF–26TRANSFER – TRANSFER UNIT
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(d) With SST and the transfer RH bearing sub-
assembly in close contact, install the transfer RH
bearing retainer sub-assembly together with SST
into the transfer case.
NOTICE:
Avoid interference between the case and the
retainer, and between the SST and the transfer
ring gear mounting case.
HINT:
If the engagement is tight, tap SST with a hammer
placing a brass bar on the center of SST.
(e) Make sure that the transfer RH bearing retainer sub-
assembly and transfer case contact closely.
(f) Tighten the 7 bolts evenly in order shown in the
illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
(g) Remove the SST.
15. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Set the dial gauge perpendicular to the ring gear
face, fix the driven pinion, and check backlash by
moving the ring gear.
Backlash:
0.10 to 0.15 mm (0.0039 to 0.0059 in.)
NOTICE:
Measure it at 3 points or more on the ring gear
periphery.
C149594E01
C149596E01
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TRANSFER – TRANSFER UNITTF–27
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(b) If the measured value is out of standard, select a
proper washer for the center differential case
tapered roller bearing on the LH side from the table
below and install it to obtain the standard value.
HINT:
When the backlash is larger or smaller than the
standard, select a thinner or thicker washer
respectively.
(c) Ring gear mounting case plate washer location is
shown in the illustration.
16. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Apply red lead primer thinly and uniformly to both
faces of the ring gear and rotate it several times.
NOTICE:
Check the tooth contact on the ring gear at 4
places or more.
MarkWasher Thickness
mm (in.)MarkWasher Thickness
mm (in.)MarkWasher Thickness
mm (in.)
AA 2.07 (0.0814) AB 2.10 (0.0826) AC 2.13 (0.0838)
BA 2.16 (0.0850) BB 2.19 (0.0862) BC 2.22 (0.0874)
CA 2.25 (0.0885) CB 2.28 (0.0897) CC 2.31 (0.0909)
DA 2.34 (0.0921) DB 2.37 (0.0933) DC 2.40 (0.0944)
EA 2.43 (0.0956) EB 2.46 (0.0968) EC 2.49 (0.0980)
FA 2.52 (0.0992) FB 2.55 (0.1003) FC 2.58 (0.1015)
GA 2.61 (0.1027) GB 2.64 (0.1039) GC 2.67 (0.1051)
HA 2.70 (0.1062) HB 2.73 (0.1074) HC 2.76 (0.1086)
JA 2.79 (0.1098) JB 2.82 (0.1110) JC 2.85 (0.1122)
KA 2.88 (0.1133) KB 2.91 (0.1145) KC 2.94 (0.1157)
LA 2.97 (0.1169) LB 3.00 (0.1181)
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TF–28TRANSFER – TRANSFER UNIT
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(b) Observe the pattern shown by red lead primer.
(c) In case of poor tooth contact, select a washer for the
driven pinion bearing front side from the following
table and replace it.
NOTICE:
If the washer thickness is changed, the backlash
will be also changed.
(d) The location of the transfer output washer for tooth
contact adjustment is shown in the illustration.
C083636E02
MarkWasher Thickness
mm (in.)MarkWasher Thickness
mm (in.)MarkWasher Thickness
mm (in.)
AA 1.20 (0.0472) AC 1.22 (0.0480) BB 1.24 (0.0488)
CA 1.26 (0.0496) CC 1.28 (0.0503) DB 1.30 (0.0511)
EA 1.32 (0.0519) EC 1.34 (0.0527) FB 1.36 (0.0535)
GA 1.38 (0.0543) GC 1.40 (0.0551) HB 1.42 (0.0559)
JA 1.44 (0.0566) JC 1.46 (0.0574) KB 1.48 (0.0582)
LA 1.50 (0.0590) LC 1.52 (0.0598) MB 1.54 (0.0606)
NA 1.56 (0.0614) NC 1.58 (0.0622) PB 1.60 (0.0629)
QA 1.62 (0.0637) QC 1.64 (0.0645)
C083656E01

TRANSFER – TRANSFER UNITTF–29
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17. ADJUST TOTAL PRELOAD
(a) Using SST(s) and a torque wrench, measure the
initial torque with the driven pinion bearing contact
with the ring gear face.
SST 09326-20011
Torque: New bearing
+0.2 to 0.4 N*m (+2.3 to 3.9 kgf*cm, 1.8
to 3.5 in.*lbf)
Used bearing
+0.15 to 0.30 N*m (+1.6 to 3.1 kgf*cm,
1.3 to 2.7 in.*lbf)
NOTICE:
Before measurement, rotate the bearing in both
directions several times to make it fit.
HINT:
Use a torque wrench with a fulcrum length of 160
mm (6.30 in.)
(b) If the value is out of standard range, select the
washer for the center differential case tapered roller
bearing RH side from the following table and
replace it.
(c) The location of the transfer ring gear mounting case
washer No. 2 for preload adjustment is show in the
illustration.
C083635E07
MarkWasher Thickness mm
(in.)MarkWasher Thickness mm
(in.)MarkWasher Thickness mm
(in.)
AA 1.47 (0.0578) AB 1.50 (0.0590) AC 1.53 (0.0602)
BA 1.56 (0.0614) BB 1.59 (0.0625) BC 1.62 (0.0637)
CA 1.65 (0.0649) CB 1.68 (0.0661) CC 1.71 (0.0673)
DA 1.74 (0.0685) DB 1.77 (0.0696) DC 1.80 (0.0708)
EA 1.83 (0.0720) EB 1.86 (0.0732) EC 1.89 (0.0744)
FA 1.92 (0.0755) FB 1.95 (0.0767) FC 1.98 (0.0779)
GA 2.01 (0.0790) GB 2.04 (0.0803) GC 2.07 (0.0814)
HA 2.10 (0.0826) HB 2.13 (0.0838) HC 2.16 (0.0850)
JA 2.19 (0.0862) JB 2.22 (0.0874) JC 2.25 (0.0885)
KA 2.28 (0.0897) KB 2.31 (0.0909) KC 2.34 (0.0921)
LA 2.37 (0.0933) LB 2.40 (0.0944) LC 2.43 (0.0956)
MA 2.46 (0.0968) MB 2.49 (0.0980) MC 2.52 (0.0992)
NA 2.55 (0.1003) NB 2.58 (0.1015)
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TF–30TRANSFER – TRANSFER UNIT
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(d) Using a chisel, stake the transfer gear nut.
18. REMOVE TRANSFER RH BEARING RETAINER SUB-
ASSEMBLY
(a) Remove the 7 bolts from the transfer RH bearing
retainer sub-assembly.
(b) Using SST, make a clearance between the transfer
RH bearing retainer sub-assembly and the transfer
case.
SST 09950-00020
(c) Remove the SST.
(d) Using SST, remove the transfer RH bearing retainer
sub-assembly from the transfer case.
SST 09520-10021
C070532
C083509
C149592E01
C082981E06