TOYOTA SIENNA 2007 Service Repair Manual

TF–28TRANSFER – TRANSFER UNIT
TF
(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
TF
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)
C083657E01

TF–30TRANSFER – TRANSFER UNIT
TF
(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

TRANSFER – TRANSFER UNITTF–31
TF
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 and transfer
ring gear mounting case washer No. 2 from the
transfer RH bearing retainer sub-assembly.
SST 09308-00010
20. INSTALL SIDE GEAR SHAFT HOLDER BEARING
(a) Install the side gear shaft holder bearing to the
transfer RH bearing retainer sub-assembly.
(b) Using snap ring pliers, install the side gear shaft
holder hole snap ring.
HINT:
Check that the side gear shaft holder hole snap ring
fits in the groove of the transfer RH bearing retainer
sub-assembly.
21. INSTALL TRANSFER RH BEARING RETAINER OIL
SEAL
(a) Using SST(s) and a press, install the transfer RH
bearing retainer oil seal No. 2 to the transfer RH
bearing retainer sub-assembly.
SST 09950-60010 (09951-00350, 09951-00560,
09952-06010), 09950-70010 (09951-07150)
NOTICE:
Carefully press-fit so that the oil seal will not be
tilted.
(b) Apply small amount of MP grease No. 2 to the oil
seal lip.
22. INSTALL NO. 2 TRANSFER RING GEAR MOUNTING
CASE WASHER
(a) Install the No. 2 selected transfer ring gear
mounting washer to the transfer RH bearing retainer
sub-assembly.
23. 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)
C083688E01
C083699
C083689E01
C083690E01

TF–32TRANSFER – TRANSFER UNIT
TF
24. INSTALL O-RING
(a) Coat the 2 O-rings with hypoid gear oil.
(b) Install the 2 O-rings to the transfer RH bearing
retainer sub-assembly.
NOTICE:
Be careful not to twist the O-ring and fit it
properly in the retainer's groove.
25. 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) Apply MP grease No. 2 thinly to area A as shown in
the illustration.
HINT:
Apply MP grease No. 2 to prevent the oil seal lip
from rolling back.
(d) Insert SST into the transfer RH bearing retainer sub-
assembly.
SST 09387-00090
NOTICE:
Insert SST straight in order not to damage the
oil seal.
C050352
C149593E01
C057487E02

TRANSFER – TRANSFER UNITTF–33
TF
(e) 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.
• Carefully check the retainer's O-ring for
damage and incorrect fitting.
HINT:
• If the engagement is tight, tap SST with a
hammer placing a brass bar on the center of
SST.
• If SST and retainer are not in close contact, the
seal for the inner end of the retainer may not be
properly aligned when the retainer goes into
position. This may result in the lip of the oil seal
being rolled back during installation.
• If SST and retainer are not in close contact, the
center of the retainer or transfer ring gear
mounting case may come out of position when
the retainer is being installed. This can cause the
lip of the oil seal to be rolled back.
(f) Make sure that the transfer RH bearing retainer sub-
assembly and transfer case contact closely.
(g) Tighten the 7 bolts evenly in order shown in the
illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
(h) Remove the SST.
C149594E01
C149596E01
C149597E01

TF–34TRANSFER – TRANSFER UNIT
TF
26. INSPECT TOTAL PRELOAD
(a) Using SST(s) and a torque wrench, measure the
initial torque with the driven pinion being in 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)
HINT:
Use a torque wrench with a fulcrum length of
160mm (6.30 in.)
27. INSTALL TRANSFER RH BEARING RETAINER OIL
SEAL
(a) Using SST(s), install the transfer RH bearing
retainer oil seal to the transfer RH bearing retainer
sub-assembly to the position as shown in the
illustration.
SST 09223-46011
NOTICE:
Install the oil seal carefully so that it will not be
tilted.
(b) Apply MP grease to the oil seal lip.
28. INSTALL TRANSFER CASE OIL SEAL
(a) Using(s), install the transfer case oil seal to the
transfer case at the position as shown in the
illustration.
SST 09387-00010, 09950-70010 (09951-07150)
NOTICE:
Install the oil seal carefully so that it will not be
tilted.
(b) Apply small amount of MP grease to the oil seal lip.
29. INSTALL CTR DIFFERENTIAL LOCK SLEEVE
(a) Coat a new O-ring with hypoid gear oil.
(b) Install the O-ring to the CTR differential lock sleeve.
NOTICE:
Be careful not to twist the O-ring and fit it
properly in the retainer's groove.
C083650E01
C083691E01
C083631E02
C050354

TRANSFER – TRANSFER UNITTF–35
TF
(c) Using SST(s), install the CTR differential lock sleeve
to the transfer case.
SST 09950-60010 (09951-00610), 09950-70010
(09951-07150)
(d) Using snap ring pliers, install the shaft snap ring.
NOTICE:
Check that the snap ring is fitted in the groove
of the ring gear mounting case.
30. INSTALL TRANSFER EXTENSION HOUSING TYPE T
OIL SEAL
(a) Using SST(s), install the transfer extension housing
type T oil seal to the transfer extension housing at
the position as shown in the illustration.
SST 09950-60010 (09951-00380, 09951-00580,
09951-07150, 09952-06010), 09950-70010
NOTICE:
Install the oil seal carefully so that it will not be
tilted.
(b) Apply small amount of MP grease No. 2 to the oil
seal lip.
31. INSTALL TRANSFER EXTENSION HOUSING DUST
DEFLECTOR
(a) Using SST(s) and press, install a new transfer
extension housing dust deflector to the transfer
extension housing sub-assembly.
SST 09950-60020 (09951-00710), 09950-70010
(09951-07150)
C083692E01
C083693
C083694E01
C083695E01

TF–36TRANSFER – TRANSFER UNIT
TF
32. INSTALL TRANSFER EXTENSION HOUSING SUB-
ASSEMBLY
(a) Apply sealant 1281 to the transfer extension
housing sub-assembly in continuous beaded from of
1.2 mm diameter as show in the illustration.
NOTICE:
• Wipe any grease off from the attaching
surfaces.
• Install the transfer extension housing sub-
assembly within 10 minutes after applying the
sealant.
(b) Install the transfer extension housing sub-assembly
to the transfer case with the 4 bolts.
Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
(c) Remove the transfer assembly from the overhaul
attachment.
33. INSTALL TRANSFER AND TRANSAXLE SETTING
STUD BOLT
(a) Install the transfer and transaxle setting stud bolts to
the parts of the transfer case as show in the
illustration.
Torque: 39 N*m (400 kgf*cm, 30 ft.*lbf)
NOTICE:
Install the sealant-coated side of the transfer
and transaxle stud bolt to the transfer case.
34. INSTALL TRANSFER CASE STRAIGHT PIN
(a) Using a plastic hammer, install the transfer case
straight pins to the transfer case as shown in thee
illustration.
C083696E01
C082800
D031105E01
C083712E01

TRANSFER – TRANSFER UNITTF–37
TF
35. INSTALL TRANSFER DYNAMIC DAMPER
(a) Install the transfer dynamic damper to the transfer
extension housing sub-assembly with the 3 bolts.
Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
36. INSTALL BREATHER OIL DEFLECTOR
(a) Install the breather oil deflector to the transfer case
cover No. 1 with the bolt.
Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)
NOTICE:
Be careful about the direction of the deflector's
fold.
37. INSTALL NO. 1 TRANSFER CASE COVER
(a) Apply sealant 1281 to the transfer case cover No. 1
in a continuous bead of 1.2 mm diameter as show in
the illustration.
NOTICE:
• Wipe any grease off from the attaching
surfaces.
• Install the transfer case cover No. 1 within 10
minutes after application of the sealant.
(b) Install the transfer case cover No. 1 to the transfer
case with 8 bolts.
Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
38. INSTALL TRANSFER CASE BREATHER PLUG
(a) Using SST(s) and a hammer, install the transfer
case breather plug to the transfer case cover No. 1.
SST 09612-10093 (09612-10061)
C051143
C067686
C083713E01
C083507
D030774E01