Toyota Venza: Reassembly

(a) Using SST and a press, press the transfer driven pinion rear bearing (outer race) to the case.

SST: 09950-60010

09951-00620

SST: 09950-70010

09951-07150

NOTICE:

Keep the transfer case horizontal using wooden blocks, etc.

(a) Apply gear oil to the inner surface of the transfer case.

*1

Transfer Driven Pinion Front Bearing (Outer Race)

*a

Turn

*b

Hold

(c) Using SST and a press, press the transfer driven pinion front bearing (inner race) into the driven pinion.

SST: 09506-30012

(a) Install the driven pinion to the transfer case.

(b) Install a new transfer pinion bearing spacer and driven pinion rear bearing (inner race) to the driven pinion.

HINT:

Install the pinion bearing spacer with the larger inner diameter facing forward as shown in the illustration.

(c) Using SST, install a new gear nut.

SST: 09326-20011

SST: 09556-16030

Torque:

Specified tightening torque :

270-420 N·m {2753-4283 kgf·cm, 199-310 ft·lbf}

NOTICE:

Do not stake the gear nut until the final preload, tooth contact and backlash adjustments are completed.

(a) Using SST and a torque wrench, measure the driven pinion preload.

SST: 09326-20011

Specified Preload (at Starting):

(b) Heat the ring gear in boiling water.

(e) After the moisture on the ring gear has completely evaporated, quickly align the matchmarks and set the ring gear to the transfer ring gear mounting case.

(a) Using SST and a press, press the ring gear mounting case bearing (inner race) to the transfer ring gear mounting case.

SST: 09387-00010

SST: 09950-70010

09951-07100

(d) Using SST and a press, press the ring gear mounting case bearing (inner race) to the transfer ring gear mounting case.

SST: 09223-00010

SST: 09726-40010

(f) Using SST and a press, press the ring gear mounting case bearing (outer race) to the transfer case.

SST: 09950-60010

09951-00680

SST: 09950-70010

09951-07200

(a) Apply gear oil to the transfer ring gear mounting case.

(a) Align the cutout on the No. 1 transfer output shaft spacer with the transfer case hole to install it as shown in the illustration.

(a) Using a brass bar and a hammer, install the No. 2 transfer ring gear mounting case washer.

HINT:

Use a No. 2 transfer ring gear mounting case washer with the same thickness as the one removed.

(a) Install the bearing cap with the 2 bolts.

Torque:

63 N·m {644 kgf·cm, 47 ft·lbf}

(a) Set a dial indicator perpendicular to a ring gear tooth tip. Secure the driven pinion in place and move the ring gear back and forth to measure the backlash.

Backlash:

0.14 to 0.25 mm (0.00551 to 0.00984 in.)

NOTICE:

Check at least 3 positions on the circumference of the ring gear.

(b) If the backlash is outside the specified range, select a ring gear mounting case washer from the table and install it to meet the specified range.

(a) Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.

*a

Proper Contact

*b

Heel Contact

*c

Face Contact

*d

Select a washer that will bring the driven pinion closer to the ring gear

*e

Toe Contact

*f

Flank Contact

*g

Select a washer that will shift the driven pinion away from the ring gear

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(d) If the tooth contact pattern is not correct, select a new transfer output shaft washer that is thicker or thinner as necessary and recheck.

NOTICE:

When the washer thickness is changed, readjust the backlash (See page ).

*a

Torque Wrench Fulcrum Length

New bearing

0.48 to 0.70 N*m (5 to 7 kgf*cm, 5 to 6 in.*lbf) + Driven pinion preload

Reused bearing

0.35 to 0.53 N*m (4 to 5 kgf*cm, 4 to 4.6 in.*lbf) + Driven pinion preload

*1

No. 2 Transfer Ring Gear Mounting Case Washer

G7

2.47 (0.0972)

M7

3.47 (0.1366)

G8

2.49 (0.0980)

M8

3.49 (0.1374)

G9

2.51 (0.0988)

M9

3.51 (0.1382)

H0

2.53 (0.0996)

N0

3.53 (0.1390)

H1

2.55 (0.1004)

N1

3.55 (0.1398)

H2

2.57 (0.1012)

N2

3.57 (0.1406)

H3

2.59 (0.1020)

N3

3.59 (0.1413)

H4

2.61 (0.1028)

N4

3.61 (0.1421)

H5

2.63 (0.1035)

N5

3.63 (0.1429)

H6

2.65 (0.1043)

N6

3.65 (0.1437)

H7

2.67 (0.1051)

N7

3.67 (0.1445)

H8

2.69 (0.1059)

N8

3.69 (0.1453)

H9

2.71 (0.1067)

N9

3.71 (0.1461)

J0

2.73 (0.1075)

P0

3.73 (0.1469)

J1

2.75 (0.1083)

P1

3.75 (0.1476)

J2

2.77 (0.1091)

P2

3.77 (0.1484)

J3

2.79 (0.1098)

P3

3.79 (0.1492)

J4

2.81 (0.1106)

P4

3.81 (0.1500)

J5

2.83 (0.1114)

P5

3.83 (0.1508)

J6

2.85 (0.1122)

P6

3.85 (0.1516)

J7

2.87 (0.1130)

P7

3.87 (0.1524)

J8

2.89 (0.1138)

P8

3.89 (0.1531)

J9

2.91 (0.1146)

P9

3.91 (0.1539)

K0

2.93 (0.1154)

Q0

3.93 (0.1547)

K1

2.95 (0.1161)

Q1

3.95 (0.1555)

K2

2.97 (0.1169)

Q2

3.97 (0.1563)

K3

2.99 (0.1177)

Q3

3.99 (0.1571)

K4

3.01 (0.1185)

Q4

4.01 (0.1579)

K5

3.03 (0.1193)

Q5

4.03 (0.1587)

K6

3.05 (0.1201)

Q6

4.05 (0.1594)

K7

3.07 (0.1209)

Q7

4.07 (0.1602)

K8

3.09 (0.1217)

Q8

4.09 (0.1610)

K9

3.11 (0.1224)

Q9

4.11 (0.1618)

L0

3.13 (0.1232)

R0

4.13 (0.1626)

L1

3.15 (0.1240)

R1

4.15 (0.1634)

L2

3.17 (0.1248)

R2

4.17 (0.1642)

L3

3.19 (0.1256)

R3

4.19 (0.1650)

L4

3.21 (0.1264)

R4

4.21 (0.1657)

L5

3.23 (0.1272)

R5

4.23 (0.1665)

L6

3.25 (0.1280)

R6

4.25 (0.1673)

L7

3.27 (0.1287)

R7

4.27 (0.1681)

L8

3.29 (0.1295)

R8

4.29 (0.1689)

L9

3.31 (0.1303)

R9

4.31 (0.1697)

M0

3.33 (0.1311)

S0

4.33 (0.1705)

M1

3.35 (0.1319)

S1

4.35 (0.1713)

M2

3.37 (0.1327)

S2

4.37 (0.1720)

M3

3.39 (0.1335)

S3

4.39 (0.1728)

M4

3.41 (0.1343)

S4

4.41 (0.1736)

M5

3.43 (0.1350)

S5

4.43 (0.1744)

M6

3.45 (0.1358)

S6

4.45 (0.1752)

(b) Using a chisel and a hammer, stake the gear nut.

(a) Using SST and a hammer, drive a new transfer case front oil seal into the case until it reaches the position shown in the illustration.

SST: 09950-60010

09951-00350

09951-00580

09952-06010

SST: 09950-70010

09951-07150

Drive in depth:

33.5 to 34.5 mm (1.319 to 1.358 in.)

NOTICE:

Make sure that the transfer case front oil seal is not tilted.

(a) Using SST and a hammer, drive a new transfer case front oil seal into the transfer case until it reaches the position in the illustration.

SST: 09608-10010

SST: 09950-70010

09951-07150

Drive in depth:

9.5 to 10.5 mm (0.374 to 0.413 in.)

(a) Using SST and a hammer, drive a new transfer case rear oil seal into the extension housing until it reaches the position shown in the illustration.

SST: 09325-20010

Drive in depth:

9.8 to 10.6 mm (0.386 to 0.417 in.)

(a) Using SST and a press, press in a new transfer extension housing dust deflector until it contacts the installation surface as shown in the illustration.

SST: 09950-60020

09951-01030

SST: 09950-70010

09951-07150

(c) Apply FIPG to the transfer extension housing sub-assembly.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(d) Install the transfer extension housing sub-assembly with the 4 bolts to the transfer case.

Torque:

26 N·m {260 kgf·cm, 19 ft·lbf}

NOTICE:

Assemble the transfer extension housing sub-assembly within 10 minutes of FIPG application.

*a

10.8 to 11.8 mm (0.425 to 0.465 in.)

*b

5.7 to 6.7 mm (0.224 to 0.264 in.)

(a) Install the transfer dynamic damper with the 3 bolts to the transfer extension housing sub-assembly.

Torque:

26 N·m {260 kgf·cm, 19 ft·lbf}

(a) Using SST and a hammer, tap in a new transfer case breather plug.

SST: 09820-00031

(a) Install the breather oil deflector with the bolt.

Torque:

6.5 N·m {66 kgf·cm, 58 in·lbf}

(c) Apply FIPG to the No. 1 transfer case cover.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(d) Install the No. 1 transfer case cover with the 6 bolts.

Torque:

20 N·m {200 kgf·cm, 14 ft·lbf}

(e) Install the No. 1 transfer case cover with 2 new bolts.

Torque:

20 N·m {200 kgf·cm, 14 ft·lbf}

(a) Install a new gasket to the transfer drain plug.

(a) Install a new gasket to the No. 1 transfer case plug.

(a) Install a new gasket to the No. 2 transfer case plug.

*a

Transaxle Side

*b

Transfer Side

*c

30 mm (1.1811 in.)

*d

12 mm (0.4724 in.)

*e

22 mm (0.8661 in.)

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