TOYOTA SIENNA 2007 Service Repair Manual

TF–8TRANSFER – TRANSFER ASSEMBLY
TF
REMOVAL
1. REMOVE ENGINE AND TRANSAXLE
HINT:
(See page EM-26)
2. REMOVE AUTOMATIC TRANSMISSION WITH
TRANSFER
HINT:
(See page AX-164)
3. REMOVE NO. 1 TRANSFER CASE PLUG
(a) Remove the No. 1 transfer case plug.
(b) Remove the No. 1 gasket from the transfer case No.
1 plug.
4. REMOVE NO. 2 TRANSFER CASE PLUG
(a) Remove the No. 2 transfer case plug.
(b) Remove the No. 2 gasket from the No. 2 transfer
case plug.
5. REMOVE TRANSFER DRAIN PLUG
(a) Remove the transfer drain plug and bleed the oil.
(b) Remove the drain gasket from the transfer drain
plug.
6. REMOVE TRANSFER ASSEMBLY
(a) Remove the 2 bolts and 6 bolts.
(b) Using a plastic hammer, remove the transfer
assembly from the transaxle assembly.
NOTICE:
• Remove the transfer assembly from the
transaxle assembly without tilting it.
• When removing the transfer assembly, do not
hold onto the oil seal parts on both sides of
the assembly.
C082977E01
C082785E01

TRANSFER – TRANSFER ASSEMBLYTF–9
TF
INSTALLATION
1. INSTALL TRANSFER ASSEMBLY
(a) Apply sealant 1281 to the transaxle assembly and
transfer assembly in continuous beaded from of 1.2
mm diameter as shown in the illustration.
NOTICE:
• Wipe any grease off from the attaching
surfaces.
• Install it within 10 minutes after applying the
sealant.
• Sealant stuck on the gasket, case oil seal and
driving plug may cause oil leakage and
seizure due to oil shortage. Care must be
taken.
(b) Install the transfer assembly to the transaxle
assembly with the 2 bolts and 6 nuts.
Torque: 69 N*m (700 kgf*cm, 51 ft.*lbf)
NOTICE:
• Check that the gasket is installed to the
transfer assembly before installing them to
the transaxle assembly.
• Install the transfer assembly to the transaxle
assembly without tilting.
• When moving the transfer assembly, do not
hold the oil seal on the both sides.
2. INSTALL AUTOMATIC TRANSMISSION WITH
TRANSFER
HINT:
(See page AX-167)
3. INSTALL ENGINE AND TRANSAXLE
HINT:
(See page EM-44)
4. INSTALL TRANSFER DRAIN PLUG
(a) Install the transfer drain plug with a new drain
gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
5. INSTALL NO. 2 TRANSFER CASE PLUG
(a) Install the No. 2 transfer case plug with a new No. 2
gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
C083714E01
C082785
C082977E01

TF–10TRANSFER – TRANSFER ASSEMBLY
TF
6. INSTALL NO. 1 TRANSFER CASE PLUG
(a) Add oil up to 0 to 5 mm below the lower side of the
plug hole.
Oil quantity:
0.9 L (0.95 US qts, 0.71 lmp. qts)
HINT:
When adding oil, pour it slowly.
(b) Install the No. 1 transfer case plug with a new No. 1
gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
7. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT:
(See page SP-4)
8. CHECK ABS SPEED SENSOR SIGNAL
HINT:
(See page BC-3)

TRANSFER – TRANSFER UNITTF–11
TF
DRIVE LINE
TRANSFER
TRANSFER UNIT
COMPONENTS
C118782E04

TF–12TRANSFER – TRANSFER UNIT
TF
C118783E03

TRANSFER – TRANSFER UNITTF–13
TF
DISASSEMBLY
1. REMOVE TRANSFER COVER GASKET
(a) Remove the transfer gasket from the transfer
assembly.
2. REMOVE TRANSFER CASE BREATHER PLUG
(a) Using a screwdriver and a hammer, remove the
transfer case breather plug from the No. 1 transfer
case cover.
NOTICE:
Be careful not to damage the contact surface of
No. 1 case cover.
3. REMOVE NO. 1 TRANSFER CASE COVER
(a) Remove the 8 bolts.
(b) Using a brass bar and a hammer, remove the No. 1
transfer case cover from the transfer case.
NOTICE:
Be careful not to damage the contact surfaces of
the case and cover.
4. REMOVE BREATHER OIL DEFLECTOR
(a) Remove the bolt and breather oil deflector from the
No. 1 transfer case cover.
C082798
C094714
C083507
C050303
C067665

TF–14TRANSFER – TRANSFER UNIT
TF
5. REMOVE TRANSFER DYNAMIC DAMPER
(a) Remove the 3 bolts and the transfer dynamic
damper from the transfer extension housing sub-
assembly.
6. REMOVE TRANSFER CASE STRAIGHT PIN
(a) Remove the 4 transfer case straight pins from the
transfer case.
7. REMOVE TRANSFER AND TRANSAXLE SETTING
STUD BOLT
(a) Remove the 4 transfer and transaxle setting stud
bolts.
8. FIX TRANSFER ASSEMBLY
(a) Fix the transfer assembly to the overhaul
attachment.
9. REMOVE TRANSFER EXTENSION HOUSING DUST
DEFLECTOR
(a) Using a plastic hammer, remove the transfer
extension housing dust deflector from the transfer
extension housing sub-assembly.
10. REMOVE TRANSFER EXTENSION HOUSING TYPE T
OIL SEAL
(a) Using SST(s), 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.
11. REMOVE TRANSFER EXTENSION HOUSING SUB-
ASSEMBLY
(a) Remove the 4 bolts.
C082802
C082788
C082978E01
C082790

TRANSFER – TRANSFER UNITTF–15
TF
(b) Using a plastic hammer, remove the transfer
extension housing sub- assembly from the transfer
case.
12. INSPECT PRELOAD
(a) Using SST(s) and a torque wrench, check the initial
torque with 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.)
13. REMOVE CTR DIFFERENTIAL LOCK SLEEVE
(a) Using snap ring pliers, remove the shaft snap ring.
(b) Using SST(s), remove the CTR differential lock
sleeve.
SST 09308-00010
C082791
C083635E01
C083637
C083638E01

TF–16TRANSFER – TRANSFER UNIT
TF
14. 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.
15. REMOVE TRANSFER CASE OIL SEAL
(a) Using SST(s), 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.
16. REMOVE TRANSFER RH BEARING RETAINER OIL
SEAL
(a) Using SST(s), remove the transfer RH bearing
retainer oil seal from the transfer RH bearing
retainer sub-assembly.
SST 09308-00010
NOTICE:
Be careful not to damage the oil-seal-fitted
surface of the retainer.
17. REMOVE TRANSFER RH BEARING RETAINER SUB-
ASSEMBLY
(a) Remove the 7 bolts from the transfer RH bearing
retainer sub-assembly.
C050311
C083630E02
C082980E01
C083509

TRANSFER – TRANSFER UNITTF–17
TF
(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
18. REMOVE O-RING
(a) Using a screwdriver with the tip protected by vinyl
tape, remove the 2 O-rings from the transfer RH
bearing retainer sub-assembly.
NOTICE:
Be careful not to damage the retainer's grooves
for the O-rings.
19. REMOVE CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Fix the transfer RH bearing retainer sub-assembly
in a vise.
(b) Using SST(s), 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-assembly.
SST 09308-00010
NOTICE:
Be careful not to damage the oil-seal-fitted
surface of the transfer RH bearing retainer sub-
assembly.
C149592E01
C082981E06
C050313
C083639E01