TOYOTA HIGHLANDER 2001 Service Repair Manual
Manufacturer: TOYOTA, Model Year: 2001, Model line: HIGHLANDER, Model: TOYOTA HIGHLANDER 2001Pages: 2572, PDF Size: 34.8 MB
Page 2511 of 2572
C67665
C82802
C82788
C82978
SST
- TRANSFERTRANSFER ASSY (4WD)
31-1 1
3089 Author: Date:
13. REMOVE BREATHER OIL DEFLECTOR
(a) Remove the bolt and breather oil deflector from the trans-
fer case cover No.1.
14. REMOVE TRANSFER DYNAMIC DAMPER
(a) Remove the 3 bolts and the transfer dynamic damper
from the transfer extension housing sub-assy.
15. REMOVE TRANSFER CASE STRAIGHT PIN
(a) Remove the 4 transfer case straight pins from the transfer case.
16. REMOVE TRANSFER & TRANSAXLE SETTING STUD BOLT
(a) Remove the 4 transfer & transaxle setting stud bolts.
17. FIX TRANSFER ASSY
(a) Fix the transfer assy to the overhaul attachment.
18. REMOVE TRANSFER EXTENSION HOUSING DUST
DEFLECTOR
(a) Using a plastic hammer, remove the transfer extension
housing dust deflector from the transfer extension hous-
ing sub-assy.
19. REMOVE TRANSFER EXTENSION HOUSING TYPE T
OIL SEAL
(a) Using SST, remove the transfer extension housing type
T oil seal from the transfer extension housing.
SST 09308-00010
NOTICE:
Be careful not to damage the oil-seal-fitted surface of the
housing and the inside surface of the bush.
Page 2512 of 2572
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C50309
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- TRANSFERTRANSFER ASSY (4WD)
3090 Author: Date:
20. REMOVE TRANSFER EXTENSION HOUSING
SUB-ASSY
(a) Remove the 4 bolts.
(b) Using a plastic hammer, remove the transfer extension
housing sub-assy from the transfer case.
21. INSPECT PRELOAD
(a) Using SST and a torque wrench, check the initial torque
within the backlash range.
SST 09326-2001 1
Torque (preload): 0.9 to 1.4 NVm
(9 to 14 kgfVcm, 8.0 to 12.4 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm
(6.30 in.)
If the value is out of standard range, replace the driven
pinion bearing.
(b) Using SST and a torque wrench, check the initial torque
while the driven pinion is in contact with the ring gear face.
SST 09326-2001 1
Torque: Preload + 0.15 to 0.30 NVm
(+1.6 to 3.1 kgfVcm, +1.3 to 2.7 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm
(6.30 in.)
If the value is out of standard range, overhaul the transfer.
22. INSPECT BACKLASH
(a) Set the dial indicator 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.
HINT:
Write down the result.
Page 2513 of 2572
C50346
K3673 C30886C83636
Proper ContactHeel ContactFace Contact
Toe ContactFlank Contact Select an adjusting washer that will bring
the driven pinion closer to the ring gear.
Select an adjusting washer that will shift
the drive pinion away from the ring gear.
C50310C83637
C51144C83638SST
- TRANSFERTRANSFER ASSY (4WD)
31-13
3091 Author: Date:
23. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVEN 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.
(b) Proper washer location is shown in the illustration.
24. REMOVE CTR DIFFERENTIAL LOCK SLEEVE
(a) Using snap ring pliers, remove the shaft snap ring.
(b) Using SST, remove the CTR differential lock sleeve.
SST 09308-00010
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SST
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31-14
- TRANSFERTRANSFER ASSY (4WD)
3092 Author: Date:
25. REMOVE O-RING
(a) Using a screwdriver with the tip protected by vinyl tape,
remove the O-ring from the CTR differential lock sleeve.
NOTICE:
Be careful not to damage the lock sleeve's groove for the
O-ring.
26. REMOVE TRANSFER CASE OIL SEAL
(a) Using SST, remove the transfer case oil seal from the
case.
SST 09308-00010
NOTICE:
Be careful not to damage the oil-seal-fitted surface of the
case.
27. REMOVE TRANSFER RH BEARING RETAINER OIL
SEAL
(a) Using SST, remove the transfer RH bearing retainer oil
seal from the transfer RH bearing retainer sub-assy.
SST 09308-00010
NOTICE:
Be careful not to damage the oil-seal-fitted surface of the
retainer.
28. REMOVE TRANSFER RH BEARING RETAINER
SUB-ASSY
(a) Remove the 7 bolts from the transfer RH bearing retainer
sub-assy .
(b) Using a screwdriver and a hammer, create a clearance
between the transfer RH bearing retainer sub-assy and
the transfer case.
NOTICE:
Be careful not to damage the transfer RH bearing retainer
sub-assy and the transfer case.
Page 2515 of 2572
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- TRANSFERTRANSFER ASSY (4WD)
31-15
3093 Author: Date:
(c) Using SST, remove the transfer RH bearing retainer sub-
assy from the transfer case.
SST 09520-10021
29. REMOVE O-RING
(a) Using a screwdriver with the tip protected by vinyl tape,
remove the 2 O-rings from the transfer RH bearing retain-
er sub-assy.
NOTICE:
Be careful not to damage the retainer's grooves for the O-
rings.
30. REMOVE CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Fix the transfer RH bearing retainer sub-assy in a vise.
(b) Using SST, remove the center differential case tapered
roller bearing RH outer race, transfer ring gear mounting
case washer No.2 and right bearing retainer oil seal No.2
from the transfer RH bearing retainer sub-assy.
SST 09308-00010
NOTICE:
Be careful not to damage the oil-seal-fitted surface of the
transfer RH bearing retainer sub-assy.
31. REMOVE SIDE GEAR SHAFT HOLDER BEARING
(a) Using snap ring pliers, remove the side gear shaft holder
hole snap ring.
(b) Remove the side gear shaft holder bearing from the trans-
fer RH bearing retainer sub-assy.
Page 2516 of 2572
C67673
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C68270C83643
SST 31-16
- TRANSFERTRANSFER ASSY (4WD)
3094 Author: Date:
32. REMOVE TRANSFER RING GEAR MOUNTING CASE
(a) Remove the transfer ring gear mounting case from the
transfer case.
33. REMOVE CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) LH side:
Using SST, remove the inner race of the center differential
case tapered roller bearing from the transfer ring gear
mounting case.
SST 09950- 40011 (09951- 04010, 09952- 04010,
09953- 04020, 09954- 04010, 09955- 04061,
09957- 04010, 09958- 04011), 09950- 60010
(09951-00420)
NOTICE:
Apply grease to the screw thread and tip of the SST before
use.
HINT:
When the roller comes off due to deformation of the gauge,
completely remove the roller and remaining inner races of the
center differential case tapered roller bearing from the transfer
ring gear mounting case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00430)
NOTICE:
Apply grease to the screw thread and tip of the SST before
use.
(b) RH side:
Using SST, remove the inner race of the center differential
case tapered roller bearing from the transfer ring gear
mounting case.
SST 09950- 40011 (09951- 04010, 09952- 04010,
09953- 04020, 09954- 04010, 09955- 04061,
09957- 04010, 09958- 04011), 09950- 60010
(09951-00360)
NOTICE:
Apply grease to the screw thread and tip of the SST before
use.
Page 2517 of 2572
C50320C83644
SST
C67676C83645
Matchmarks
C67677
C99000
C82795
SST
- TRANSFERTRANSFER ASSY (4WD)
31-17
3095 Author: Date:
HINT:
When the roller comes off due to deformation of the gauge,
completely remove the roller and remaining inner races of the
center differential case tapered roller bearing from the transfer
ring gear mounting case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00360)
NOTICE:
Apply grease to the screw thread and tip of the SST before
use.
34. REMOVE RING GEAR
(a) Put matchmarks on the transfer ring gear mounting case
and the ring gear.
(b) Remove the 12 bolts.
(c) Using a plastic hammer, remove the ring gear by tapping
around its periphery.
NOTICE:
Do not damage the teeth of the ring gear.
HINT:
If the runout is too large, replace the transfer ring rear mounting
case.
35. INSPECT RUNOUT OF TRANSFER RING GEAR
MOUNTING CASE
(a) Using a dial indicator, check the transfer ring gear mount-
ing case runout.
Maximum runout: 0.03 mm (0.0012 in.)
HINT:
If the runout is too large, replace the center differential control
coupling assy or transfer ring gear mounting case.
36. REMOVE DRIVEN PINION
(a) Using SST and a hammer, unstake the transfer gear nut.
SST 09930-00010
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SST
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C50329
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- TRANSFERTRANSFER ASSY (4WD)
3096 Author: Date:
(b) Using SST, remove the transfer gear nut.
SST 09326-2001 1, 09556-16030
(c) Using a press, remove the driven pinion, transfer driven
pinion rear bearing inner race and transfer pinion bearing
spacer.
NOTICE:
Put a shop rag around to help prevent the driven pin-
ion from being dropped.
Place something like wooden blocks under the case
to keep it level.
37. REMOVE TRANSFER DRIVEN PINION FRONT
BEARING
(a) Using SST and a press, remove the transfer driven pinion
front bearing inner race from the driven pinion.
SST 09950-00020
38. REMOVE TRANSFER DRIVEN PINION FRONT
BEARING
(a) Using a brass bar and a hammer, lightly strike the center
differential case tapered roller bearing LH outer race at 2
points to remove it from the transfer case.
39. REMOVE TRANSFER OUTPUT WASHER
(a) Remove the ring gear mounting case plate washer from the transfer case.
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- TRANSFERTRANSFER ASSY (4WD)
31-19
3097 Author: Date:
40. REMOVE CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Using a brass bar and a hammer, lightly strike the transfer
driven pinion front bearing outer race at 2 points to re-
move it from the transfer case.
41. REMOVE RING GEAR MOUNTING CASE PLATE WASHER
(a) Remove the transfer output washer from the transfer case.
42. REMOVE TRANSFER DRIVEN PINION REAR
BEARING
(a) Using a brass bar and a hammer, lightly strike the transfer
driven pinion rear bearing outer race at 2 points to remove
it from the transfer case.
43. INSTALL TRANSFER DRIVEN PINION REAR
BEARING
(a) Using SST 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 wooden blocks under the case to
keep its level.
44. INSTALL TRANSFER OUTPUT WASHER
(a) Install the transfer output washer to the transfer case.
HINT:
Reuse the washer.
45. INSTALL TRANSFER DRIVEN PINION FRONT
BEARING
(a) Install the transfer driven pinion front bearing outer race
to the transfer case with SST, bolt and nut.
SST 09950- 60020 (09951- 00750, 09951- 00770,
09951-00810), 09316-60011 (09316-00061)
Page 2520 of 2572
C50336C83648
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C50338
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31-20
- TRANSFERTRANSFER ASSY (4WD)
3098 Author: Date:
46. INSTALL RING GEAR MOUNTING CASE PLATE WASHER
(a) Install the ring gear mounting case plate washer to the transfer case.
HINT:
Reuse the washer.
47. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Using SST 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)
48. INSTALL TRANSFER DRIVEN PINION FRONT
BEARING
(a) Using SST and a press, install the transfer driven pinion
front bearing inner race to the driven pinion.
SST 09316-6001 1 (09316-00041)
49. INSTALL DRIVEN PINION
(a) Install the driven pinion to the transfer case.
(b) Install a new transfer pinion bearing spacer and a new
transfer driven pinion rear bearing inner race to the driven
pinion.