TOYOTA SEQUOIA 2001 Service Repair Manual

F19291
± TRANSFERTRANSFER ASSEMBLY
TR±15
2953 Author: Date:
2005 SEQUOIA (RM1146U)
(b) Remove the low planetary ring gear from the transfer front
case.

TR0DG±01
F19291
Front
F19292
F19289
F19267
Front
F19266
TR±16
± TRANSFERTRANSFER ASSEMBLY
2954 Author: Date:
2005 SEQUOIA (RM1146U)
REASSEMBLY
1. INSTALL LOW PLANETARY RING GEAR
(a) Install the low planetary ring gear to the front case.
(b) Using a screwdriver, install the snap ring.
2. INSTALL CASE PLUG
Install the head pin, compression spring and case plug to the
transfer front case.
Torque: 18.6 N´m (190 kgf´cm, 14 ft´lbf)
3. INSTALL LOW PLANETARY GEAR
(a) Install the thrust bearing race No. 1 and low planetary
gear bearing to the input shaft.
(b) Install the input shaft to the low planetary gear.
(c) Install the ball, planetary carrier washer and input gear
stopper.

F19299
F19300
SST
F19263
± TRANSFERTRANSFER ASSEMBLY
TR±17
2955 Author: Date:
2005 SEQUOIA (RM1146U)
(d) Select a snap ring that allows for 0.05 to 0.15 mm
(0.0020 to 0.0059 in.) axial play.
MarkThickness mm (in.)
A2.10 to 2.15 (0.0827 to 0.0846)
B2.15 to 2.20 (0.0846 to 0.0866)
C2.20 to 2.25 (0.0866 to 0.0886)
D2.25 to 2.30 (0.0886 to 0.0906)
E2.30 to 2.35 (0.0906 to 0.0925)
F2.35 to 2.40 (0.0925 to 0.0945)
G2.40 to 2.45 (0.0945 to 0.0965)
H2.45 to 2.50 (0.0965 to 0.0984)
J2.50 to 2.55 (0.0984 to 0.1004)
K2.55 to 2.60 (0.1004 to 0.1024)
L2.60 to 2.65 (0.1024 to 0.1043)
M2.65 to 2.70 (0.1043 to 0.1063)
N2.70 to 2.75 (0.1063 to 0.1083)
P2.75 to 2.80 (0.1083 to 0.1102)
Q2.80 to 2.85 (0.1102 to 0.1122)
R2.85 to 2.90 (0.1122 to 0.1142)
S2.90 to 2.95 (0.1142 to 0.1161)
T2.95 to 3.00 (0.1161 to 0.1181)
U3.00 to 3.05 (0.1181 to 0.1201)
(e) Using a snap ring expander, install a new snap ring.
4. INSTALL OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the case upper surface.
SST 09316 ± 60011 (09316 ± 00011)
(b) Coat the lip of the oil seal with MP grease.
5. INSTALL LOW PLANETARY GEAR WITH INPUT
SHAFT
(a) Install the low planetary gear with the input shaft to the
transfer front case.

F19262
F19261
F19301
F19259
F19258
TR±18
± TRANSFERTRANSFER ASSEMBLY
2956 Author: Date:
2005 SEQUOIA (RM1146U)
(b) Using a snap ring expander, install the snap ring.
6. INSTALL OIL PUMP GEAR
7. INSTALL OIL PUMP
(a) Coat a new O±ring with gear oil and install it to the oil
pump.
(b) Install the oil pump with the 3 bolts.
Torque: 7.5 N´m (76 kgf´cm, 66 in.´lbf)
8. INSTALL OIL SEPARATOR
(a) Install the magnet to the transfer front case.
(b) Install the oil separator with the 3 bolts.
Torque: 7.5 N´m (76 kgf´cm, 66 in.´lbf)

F19257
F19346
F19253
F19252
F19251
± TRANSFERTRANSFER ASSEMBLY
TR±19
2957 Author: Date:
2005 SEQUOIA (RM1146U)
9. INSTALL TRANSFER SHIFT ACTUATOR
(a) Install the transfer shift actuator with the 3 bolts.
Torque: 20 N´m (204 kgf´cm, 15 ft´lbf)
(b) Using a screwdriver and hammer, drive in the snap ring.
10. INSTALL REAR NO. 2 STOPPER TRANSFER SHIFT
SHAFT
11. INSTALL REAR OUTPUT SHAFT ASSEMBLY, GEAR
SHIFT FORK NO. 1, FRONT DRIVE CHAIN AND DRIV-
EN SPROCKET
(a) Install the rear output shaft assembly, gear shift fork No.
1 and driven sprocket to the front drive chain.
(b) Install the rear output shaft assembly, gear shift fork No.
1, driven sprocket and front drive chain to the transfer
case rear.
HINT:
Check that the rear output shaft and driven sprocket turn slight-
ly.

F19250
F19304
F19305
F19247
F19307
TR±20
± TRANSFERTRANSFER ASSEMBLY
2958 Author: Date:
2005 SEQUOIA (RM1146U)
(c) Using a snap ring expander, install the snap ring.
(d) Using a screwdriver and hammer, drive in the snap ring.
(e) Using a screwdriver and hammer, drive in the snap ring.
12. INSTALL FRONT NO. 2 STOPPER SHIFT SHAFT
13. INSTALL FRONT DRIVE SHIFT FORK SHAFT
(a) Install the 2 shift inter±lock pins.
(b) Turn the front drive shift fork shaft, and install it on the rear
case aligning the cutout with the inter±lock pin.
14. INSTALL SHIFT SHAFT STOPPER
Install the shift shaft stopper with the bolt.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)

F19308
F19306
FIPG
F19244
F19243
F19309
SST
± TRANSFERTRANSFER ASSEMBLY
TR±21
2959 Author: Date:
2005 SEQUOIA (RM1146U)
15. INSTALL GEAR SHIFT FORK NO. 2 AND HIGH AND
LOW CLUTCH SLEEVE
(a) Install the gear shift fork No. 2 and high and low clutch
sleeve with the bolt.
Torque: 24 N´m (245 kgf´cm, 18 ft´lbf)
(b) Install the spacer and output shaft front needle roller bear-
ing.
16. INSTALL TRANSFER CASE REAR
(a) Apply FIPG to the transfer case rear, as shown.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or equiva-
lent
(b) Install the clamp and transfer case rear with the
12 bolts.
Torque: 28 N´m (286 kgf´cm, 21 ft´lbf)
17. INSTALL TRANSFER EXTENSION HOUSING
(a) Install the collar and 2 transfer output washers.
(b) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the housing upper surface.
SST 09223±46011, 09631±32020
(c) Coat the lip of the oil seal with MP grease.

F19310
FIPG
F19242
F19311
SST
F19312
Front: Rear: TR±22
± TRANSFERTRANSFER ASSEMBLY
2960 Author: Date:
2005 SEQUOIA (RM1146U)
(d) Apply FIPG to the transfer extension housing, as shown.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or equiva-
lent
(e) Apply sealant to the bolt threads.
FIPG:
Part No. 08826±00080, THREE BOND 1334, LOCTITE
242 or equivalent
(f) Install the transfer extension housing with the 5 bolts.
Torque: 12 N´m (122 kgf´cm, 9 ft´lbf)
18. INSTALL FRONT OUTPUT SHAFT COMPANION
FLANGE
(a) Using SST and a hammer, drive in a new oil seal.
SST 09950±60010 (09951±00320), 09950±70010
(09951±07100)
(b) Coat the lip of the oil seal with MP grease.
(c) Install the front output shaft companion flange to the driv-
en sprocket.
(d) Using SST to hold the front output shaft companion
flange, install a new companion flange lock nut.
Torque: 118 N´m (1,203 kgf´cm, 87 ft´lbf)
SST 09330±00021
(e) Using a chisel and hammer, stake the companion flange
lock nut.
19. INSTALL REAR OUTPUT SHAFT COMPANION
FLANGE
Using SST, install the rear output shaft companion flange in the
same way as the front output shaft companion flange.
Torque: 118 N´m (1,203 kgf´cm, 87 ft´lbf)
SST 09330±00021

F19239
F19313
SST
F19314
FIPG
F19238
± TRANSFERTRANSFER ASSEMBLY
TR±23
2961 Author: Date:
2005 SEQUOIA (RM1146U)
20. INSTALL BREATHER OIL DEFLECTOR
21. INSTALL TRANSFER CASE COVER
Install the transfer case cover with the 4 bolts.
Torque: 18 N´m (184 kgf´cm, 13 ft´lbf)
22. INSTALL FRONT BEARING RETAINER
(a) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the retainer upper surface.
SST 09950±60010 (09951±00590), 09950±70010
(09951±07100)
(b) Coat the lip of the oil seal with MP grease.
(c) Apply FIPG to the front bearing retainer, as shown.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or
equivalent
(d) Apply sealant to the bolt threads.
FIPG:
Part No. 08826±00080, THREE BOND 1334, LOCTITE
242 or equivalent
(e) Install the front bearing retainer with the 5 bolts.
Torque: 11.5 N´m (117 kgf´cm, 8 ft´lbf)

TR00F±08
F19234

Front Bearing

Non±reusable partDriven Sprocket
Rear Bearing
TR±24
± TRANSFERDRIVEN SPROCKET
2962 Author: Date:
2005 SEQUOIA (RM1146U)
DRIVEN SPROCKET
COMPONENTS