105 Series Overhaul - HF1A

TR−1
TRANSFER (Part−Time 4WD Type) − TRANSFER SYSTEM
TRANSFER SYSTEM
TR05D−01
PRECAUTION
NOTICE:
When working with FIPG material, you must observe the following items.
S Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
S Thoroughly clean all components to remove all the loose material.
S Clean both sealing surfaces with a non−residue solvent.
S Apply FIPG in an approx. 1.2 mm (0.047 in.) wide bead along the sealing surface.
S Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be re-
moved and reapplied.
LAND CRUISER (W/G) (RM616E)

TR−2
TRANSFER (Part−Time 4WD Type) − TROUBLESHOOTING
TROUBLESHOOTING
TR05E−01
PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area See page
1. Oil (Level low) TR−6
2. Oil (Wrong) TR−6
Noise
3. Gear (Worn or damaged) TR−11
4. Bearing (Worn or damaged) TR−11
1. Oil (Level too high) TR−6

2. Gasket (Damaged) TR−6
Oil leakage
3. Oil seal (Worn or damaged) TR−11
4. O−Ring (Worn or damaged) TR−11
1. Transfer shift lever assembly (Faulty) TR−45

2. w/ One touch 2−4 selector system (Faulty) TR−50
Hard to shift or will not shift
3. Synchronizer ring (Worn or damaged) M/T TR−26
4. Shift key spring (Damaged) M/T TR−26
1. Locking ball spring (Damaged) TR−11

2. Shift fork (Worn) TR−11
Jumps out of gear

TR−1
TRANSFER (Part−Time 4WD Type) − TROUBLESHOOTING
TROUBLESHOOTING
TR08W−01
PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area See page
1. Oil (Level low) *
2. Oil (Wrong) *
Noise
1. Oil (Level too high) *

2. Gasket (Damaged) *
Oil leakage
3. Oil seal (Worn or damaged) TR−2
4. O−Ring (Worn or damaged) TR−2
1. Transfer shift lever assembly (Faulty) *

2. w/ One touch 2−4 selector system (Faulty) *
3. Synchronizer ring (Worn or damaged) TR−2
Hard to shift or will not shift
TR−20
4. Shift key spring (Damaged) TR−20
TR−25
1. Locking ball spring (Damaged) TR−2

2. Shift fork (Worn) TR−2
Jumps out of gear
*: See Pub. No. RM616E
LAND CRUISER SUP (RM695E)

TR−3
TRANSFER (Part−Time 4WD Type) − TRANSFER UNIT
TRANSFER UNIT
TR05F−01
COMPONENTS
w/o One Touch 2−4 Selector System (M/T):
Separate Seat:
Transmission Shift Transfer Shift Lever Knob
Lever Knob
Front Console Box
Transfer Shift Lever Assembly

6.5 (66, 48 in.·lbf) x6
19 (190, 14)
Shift Lever Boot
Retainer
106 (1,080, 78)
Shift Lever Boot

z Gasket
Neutral Position Switch

L4 Position Switch
Connector
Connector Rear Propeller Shaft
Transfer 4WD Position
Switch Connector 106 (1,080, 78)
No.1 Speed
Sensor Connector
Bench Seat: 13 (130, 9) 69 (700, 51)
12 (120, 9) 69 (700, 51) 69 (700, 51)
12 (120, 9) Breather Hose

Wave Washer Wave Washer
Transfer
Transfer Case Protector
Transfer Shift Lever Rod 69 (700, 51)
Assembly
69 (700, 51)
28 (290, 21)
80 (820, 59)
Crossmember
80 (820, 59)
50 (510, 37)
74 (750, 54)
50 (510, 37)
Front Propeller Shaft
N·m (kgf·cm, ft·lbf) : Specified torque

z Non−reusable part D02816

TR−4
w/ One Touch 2−4 Selector System (M/T):
Separate Seat:
Transfer Shift Lever Knob
Transmission Shift
Lever Knob
Front Console Box

6.5 (66, 58 in.·lbf) x6
19 (190, 14)
Shift Lever Boot
Retainer
106 (1,080, 78)
Shift Lever Boot

z Gasket
L4 Position Switch Neutral Position
Connector Switch Connector
Rear Propeller Shaft
106 (1,080, 78)
Switch Connector
No.1 Speed Sensor Connector
Motor Actuator Connector
Breather Hose
Bench Seat: Transfer Shift Lever
Rod Assembly 69 (700, 51) 69 (700, 51)
Bushing Wave
Washer
Wave Washer
12 (120, 9)
Transfer
Plate Washer
Clip 69 (700, 51) Transfer Case Protector
69 (700, 51)
28 (290, 21)
80 (820, 59) Crossmember
80 (820, 59)
50 (510, 37)
74 (750, 54)
50 (510, 37)


TR−5
A/T:
106 (1,080, 78)
L4 Position Switch 106 (1,080, 78)

Connector
Motor Actuator Neutral Position

Connector Switch Connector

Switch Connector Rear Propeller Shaft
No.1 Speed Sensor Connector
Breather Hose 69 (700, 51)

Clip
Plate Washer 69 (700, 51)
Wave Washer
Bushing
Transfer Shift Lever
Rod Assembly
69 (700, 51)
Ground Cable
Transfer Case Protector
69 (700, 51)
69 (700, 51)
Transfer
28 (290, 21)
80 (820, 59)
Crossmember
80 (820, 59)
50 (510, 37)
74 (750, 54)
50 (510, 37)

D02818

TR−6
TR05G−01
REMOVAL
1. Separate Seat (M/T):
REMOVE TRANSFER SHIFT LEVER ASSEMBLY
(a) Remove the transmission and transfer shift lever knobs.
(b) Remove the front console box.
(See page BO−124)
(c) Remove the 6 bolts and shift lever boot retainer.
Torque: 6.5 N·m (66 kgf·cm, 58 in.·lbf)
(d) Remove the shift lever boot.
(e) Remove the 4 bolts, gasket and transfer shift lever as-
sembly.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
2. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
3. REMOVE FRONT AND REAR PROPELLER SHAFTS
(See page PR−2)
4. REMOVE TRANSFER CASE PROTECTOR

Remove the 3 bolts and transfer case protector.
D02645
Filler Plug 5. DRAIN TRANSFER OIL

Oil Level
0 − 5 mm Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 1.5 liters (1.6 US qts, 1.3 Imp. qts)
Drain Plug D02809
6. w/o One Touch 2−4 Selector System, Bench Seat

(M/T):
REMOVE TRANSFER SHIFT LEVER ROD ASSEMBLY
Remove the 2 nuts, wave washers and transfer shift lever rod
assembly.
D02810

TR−7
N H4 HINT:
Shift Lever Rod
At the time of installation, please refer to the following items.
S Adjust the shift lever rod length:
Loosen the stopper nuts of the transfer shift lever rod as-
0 mm sembly at 2 positions and ensure that the shift lever rod
turns freely. By turning the shift lever rod, length of the
Shift Lever
Pin shift lever rod can be adjusted, as both ends of the shift
lever rod are male screws. To position the shift lever, ad-
Stopper Nut Shift Lever Cap D02811 just the shift lever rod length so that the clearance be-
tween the shift lever pin and shift lever cap is 0 mm in H4
position. If the shift lever rod is turned or loosened exces-
sively, shift lever pin might not move down when shifting
from N to H4, so make sure to perform the following op-
eration check.
S Perform the operation check:
After positioning the shift lever pin, repeat shifting from H4
to N to H4. Check that the shift lever pin moves down se-
curely when shifting from N to H4 and functions as a shift
stopper when shifting from H4 to N (Several times). If the
shift lever pin does not move down securely, adjust the
length of the shift lever rod and perform the operation
check again. After performing the above check, tighten
the stopper nuts to the specified torque.
7. w/ One Touch 2−4 Selector System, Bench Seat (M/T):

REMOVE TRANSFER SHIFT LEVER ROD ASSEMBLY
(a) Remove the clip, plate washer, wave washer and bushing
from the transfer shift lever shaft.
(b) Remove the nut, wave washer and transfer shift lever rod
assembly.
D02812
HINT:
Shift Lever Shaft
At the time of installation, please refer to the following item.
Ensure that the shift lever shaft is perpendicular at the center-
line. Shift the transfer outer lever in the neutral position and
Front position the transfer shift lever rod assembly. After positioning
the transfer shift lever rod assembly, tighten the nut of the trans-
90˚
fer outer lever and transfer shift lever rod assembly end to the
Centerline specified torque.
Transfer Outer Lever D02813

TR−8
8. A/T:
DISCONNECT TRANSFER SHIFT LEVER ROD AS-
SEMBLY
(a) Remove the clip, plate washer, wave washer and bush-
ing.
(b) Disconnect the transfer shift lever rod assembly from the
transfer shift lever shaft.
D01618
Wooden Block 9. REMOVE CROSSMEMBER

(a) Support the transmission, as shown.
NOTICE:
A/T:
Use a wooden block so not to damage the transmission oil
pan.
(b) Remove 8 bolts, 2 nuts and crossmember.
Torque:
Q09803 Bolt: 50 N·m (510 kgf·cm, 37 ft·lbf)
Nut: 74 N·m (750 kgf·cm, 54 ft·lbf)
10. w/o One Touch 2−4 Selector System (M/T):
Hose Clip
DISCONNECT BREATHER HOSE
HINT:
Assemble the clip to the position shown in the illustration.
From the hose end to the clip end:
Pipe 2 mm (0.08 in.) or more
2 mm (0.08 in.)
or More
D02814
11. w/ One Touch 2−4 Selector System (M/T) & A/T:

5 mm (0.20 in.)
DISCONNECT BREATHER HOSE
or More
HINT:
Assemble the clip to the position shown in the illustration.
Hose From the hose end to the clip end:
5 mm (0.20 in.) or more
Clip Pipe
12. DISCONNECT FOLLOWING CONNECTOR FROM
D03203 TRANSFER
S No.1 speed sensor connector
S L4 position switch connector
S Neutral position switch connector
S Transfer 4WD position switch connector
S w/ One Touch 2−4 Selector System (M/T) & AT:
Motor actuator connector
13. A/T:
DISCONNECT GROUND CABLE
Remove the bolt and disconnect the ground cable from the
transfer.

TR−9
14. JACK UP TRANSFER SLIGHTLY

Using a transmission jack, support the transfer.
15. REMOVE TRANSFER FROM TRANSMISSION
(a) Disconnect the wire harness from the transfer.
(b) Remove the 6 transfer adaptor rear mounting bolts.
(c) Pull out the transfer down and toward the rear.
D02815

TR−10
TR05H−01
INSTALLATION
Installation is in the reverse order of removal (See page TR−6).
HINT:
After installation, do the road test.

TR−11
TRANSFER (Part−Time 4WD Type) − TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
TR05I−01
COMPONENTS
w/o One Touch 2−4 Selector System:
Shift Outer Lever
Separate Seat (M/T): 12 (120, 9) Lever Lock Pin
Shift Outer L 19 (190, 14)

Washer
Lever L 19 (190, 14) z Oil Seal
Shift Inner Lever Shaft
Transfer 4WD Straight Spring Shift Inner Lever
Position Switch Pin Ball E−Ring
37 (380, 27) 12 (120, 9)
Snap Ring
Screw Plug
L 19 (190, 14) Plate Washer
Oil Receiver
Spring
Compression
Ball
z Gasket Spring Breather Hose
x6 Front Drive Shift

Fork Shaft
37 (380, 27) No.2 Shift Fork Front Case
z Oil Seal
Front Drive Clutch Sleeve
L4 Position Neutral Position Switch
Front Extension Housing 37 (380, 27) Lock Nut
Switch
37 (380, 27) z 127 (1,300, 94)
High and Low Shift z Gasket
Fork Shaft z O−Ring
z Gasket 37 (380, 27)
Slotted Spring Pin Speed Sensor
Bearing Outer Drive Gear x9 Companion
Race Spacer Flange
No.1 Shift 12 (120, 9) 37 (380, 27) Dust Deflector
Fork Rear Extension Housing
x8
Oil Receiver Pipe 11 (115, 8)
Rear Case
Output Shaft Speed Sensor Driven Gear
Assembly
Bearing Outer Race
Adjusting
Shim Case Cover
18 (185, 13) z Gasket z Gasket x5

Oil Receiver Pipe Filler Plug
Drain Plug
Bearing Outer Race 37 (380, 27)
37 (380, 27)
Bearing Outer Race L 37 (380, 27)
Snap Ring
Idler Gear
Assembly
Input Shaft Assembly

z Non−reusable part
L Precoated part D01983

TR−12
w/ One Touch 2−4 Selector System:

Motor Actuator
Shift Outer Lever
18 (185, 13)
12 (120, 9) Lever Lock Pin
Separate Seat (M/T):
Lever Washer
Output
z Oil Seal
Gear Spring
Transfer 4WD Shift Inner Lever Shaft
Ball L 19 (190, 14)
Position Switch
37 (380, 27) L 19 (190, 14) 12 (120, 9)
Snap Ring
Screw Plug
L 19 (190, 14) Oil Receiver
Spring Front Drive Shift
Ball Fork Shaft
z Gasket Breather Hose
x6
No.2 Shift
37 (380, 27)
Fork z Oil Seal Front Case

Neutral Position Switch
L4 Position
Front Extension Housing 37 (380, 27) Lock Nut
Switch
37 (380, 27) z 127 (1,300, 94)
z Gasket
High and Low Shift
Fork Shaft z O−Ring
z Gasket 37 (380, 27)
Slotted Spring Pin Speed Sensor
Bearing Outer Drive Gear x9 Companion
Race Flange
No.1 Shift 12 (120, 9) Spacer Dust Deflector
37 (380, 27)
Fork Rear Extension Housing
x8
Rear Case
Output Shaft Speed Sensor Driven Gear
Assembly
Adjusting Case Cover
Shim
Oil Receiver z Gasket x5
Pipe z Gasket
Filler Plug
18 (185, 13) Drain Plug
37 (380, 27) L 37 (380, 27)
37 (380, 27)
Bearing Outer Race Bearing Outer
Race
Bearing Outer Race Snap Ring
Idler Gear Assembly

TR−2
TRANSFER ASSEMBLY
TR08X−01
COMPONENTS
w/o One touch 2−4 selector system:
Front Drive Shift Fork Shaft
w/ Dual mode automatic locking hub:
Separate seat (M/T): 12 (120, 9)
Screw Plug Shift Outer Lever
Lever Compression Lever Lock Pin
Spring
Washer
z Oil Seal
Snap Ring Spring Shift Inner Lever Shaft
Transfer 4WD Shift Inner Lever
Plate Washer Ball E−Ring
Position Switch 12 (120, 9)
37 (380, 27) Straight
Screw Plug Pin
Front Drive Oil Receiver
L 19 (190, 14) Gear Piece
Spring No. 2 Shift Fork
Ball z Snap Ring Breather Hose
z Gasket
No. 2 Synchronizer
x6 Inner Ring
No. 2 Synchronizer Front Case
Middle Ring z Oil Seal Neutral Position Switch
37 (380, 27) No. 2 Synchronizer 37 (380, 27)
Lock Nut
Outer Ring L4 Position Switch z 127 (1,300, 94)
37 (380, 27)
z O−Ring
High and Low Shift
Front Extension Housing z Gasket
Fork Shaft z Gasket
Speed Sensor 37 (380, 27)
Slotted Spring Pin Drive Gear
37 (380, 27)
x9 Companion
Bearing Outer Flange
12 (120, 9) Dust Deflector
No. 1 Shift Fork Race
Rear Extension Housing
x8
Oil Receiver Pipe Spacer Speed Sensor Driven
Rear Case Gear
11 (115, 8)
Output Shaft Assembly
Bearing Outer Race
Adjusting
Shim Case Cover
18 (185, 13) z Gasket z Gasket

x5
Filler Plug
Drain Plug
Bearing Outer Race 37 (380, 27) L 37 (380, 27)
Bearing Outer Race Snap Ring
Idler Gear Assembly


TR−13
TR05J−01
DISASSEMBLY
1. REMOVE BREATHER HOSE
2. REMOVE SPEED SENSOR DRIVEN GEAR
Remove the bolt and speed sensor driven gear.
3. w/ One Touch 2−4 Selector System:

REMOVE MOTOR ACTUATOR
Remove the 4 bolts and motor actuator.
D02690
HINT:
At the time of reassembly, please refer to the following items.
S Set the motor actuator in 4WD condition.
Q04610
S Apply FIPG to the motor actuator.

FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
4 mm (0.16 in.)
REMOVE OUTPUT GEAR FROM FRONT CASE
FIPG
D02666
5. REMOVE SCREW PLUG, SPRING AND BALL

(a) Using a torx socket wrench (T40), remove the 4 screw
plugs.
HINT:
At the time of reassembly, please refer to the following item.
Apply sealant to the screw plug threads.
Sealant: Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
D01985 Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(b) Using a magnetic finger, remove the 2 springs and balls.
TR−14
6. REMOVE TRANSFER INDICATOR SWITCH

Remove the transfer 4WD position switch, L4 position switch,
neutral position switch and 3 gaskets.
7. REMOVE OUTPUT SHAFT COMPANION FLANGE

(a) Using a chisel and hammer, unstake the staked part of the
nut.
D01986
(b) Using SST to hold the flange, remove the nut and O−ring.
SST 09330−00021
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
(c) Remove the companion flange.
HINT:
If necessary, tap the companion flange lightly with a plastic
hammer.
SST D01987
(d) Remove the speed sensor drive gear from the companion
flange.
HINT:
Align the companion flange grooves with the projections on the
speed sensor drive gear.
D01988
(e) Using SST, remove the dust deflector from the companion
flange.
SST 09950−40011 (09951−04020, 09952−04010,
09953−04030, 09954−04010, 09955−04060,
09957−04010, 09958−04010), 09950−60010
SST (09951−00400)
D01989

TR−15
HINT:
Using SST and a press, install the dust deflector to the compan-
ion flange.
SST SST 09316−20011, 09316−60011 (09316−00011)
TF1087
8. REMOVE FRONT EXTENSION HOUSING

Remove the 6 bolts and front extension housing.
HINT:
If necessary, tap the front extension housing lightly with a plas-
tic hammer.
D01990
HINT:
FIPG Apply FIPG to the front extension housing.
3 mm (0.12 in.) FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
D01991

REMOVE FRONT DRIVE CLUTCH SLEEVE, NO.2
SHIFT FORK AND FRONT DRIVE SHIFT FORK SHAFT
(a) Remove the front drive clutch sleeve, No.2 shift fork and
front drive shift fork shaft from the front case.
HINT:
Make sure to install the front drive clutch sleeve in the correct
Front
D02808 direction.
(b) Using 2 screwdrivers and a hammer, drive out the 3 snap

rings from the front drive shift fork shaft.
(c) Separate the front drive shift fork shaft and No.2 shift fork.
Q02950

TR−16
10. w/o One Touch 2−4 Selector System:

REMOVE FRONT DRIVE CLUTCH SLEEVE AND NO.2
SHIFT FORK
(a) Using 2 screwdrivers and a hammer, tap out the snap ring
from the front drive shift fork shaft.
D01992
(b) Remove the front drive clutch sleeve, No.2 shift fork, 2
plate washers and compression spring.
HINT:
direction.
Front
D01993
11. REMOVE REAR EXTENSION HOUSING

Remove the 9 bolts and rear extension housing.
HINT:
If necessary, tap the rear extension housing lightly with a plastic
hammer.
D01994
FIPG
HINT:
3 mm (0.12 in.) At the time of reassembly, please refer to the following item.
Apply FIPG to the rear extension housing.
equivalent
D01995
12. REMOVE SPACER FROM OUTPUT SHAFT
D01996

TR−17
13. REMOVE ADJUSTING SHIM FOR IDLER GEAR TA-

PER ROLLER BEARING
D02790
HINT:
A Select an adjusting shim for the idler gear taper roller bearing.
S Using vernier calipers, measure the clearance of the di-
mension ”A”.
S Lightly hold down the bearing outer race in the thrust
direction to eliminate any looseness before making the
measurement.
D02751 S Calculate the required thickness of the adjusting shim.
Thickness: Dimension ”A” + [0.014 − 0.042 mm
(0.0006 − 0.0017 in.)]
S From the following table, select a shim so that its thick-
ness is within the range of the calculation.
Mark Thickness mm (in.) Mark Thickness mm (in.)
2 0.30 (0.0118) 8 3.20 (0.1260)
3 0.45 (0.0177) 9 3.40 (0.1339)
4 2.40 (0.0945) 10 3.60 (0.1417)
5 2.60 (0.1024) 11 3.80 (0.1496)
6 2.80 (0.1102) 12 4.00 (0.1575)
7 3.00 (0.1181) 13 0.55 (0.0216)
14. REMOVE ADJUSTING SHIM FOR OUTPUT SHAFT TA-

PER ROLLER BEARING
D02791

TR−18
HINT:
Select an adjusting shim for the output shaft taper roller bear-
B
ing.
S Using vernier calipers, measure the clearance of the di-
mension ”B”.
S Lightly hold down the bearing outer race in the thrust
D02752 measurement.
S Calculate the required thickness of the adjusting shim.
Thickness: Dimension ”B” + [0.070 − 0.034 mm
(0.0028 − 0.0013 in.)]
S From the following table, select a shim so that its thick-
B 0.30 (0.0118) H 1.80 (0.0709)
C 0.45 (0.0177) J 2.00 (0.0787)
D 1.00 (0.0394) K 2.20 (0.0866)
E 1.20 (0.0472) L 2.40 (0.0945)
F 1.40 (0.0551) M 2.60 (0.1024)
G 1.60 (0.0630) N 0.55 (0.0216)
15. REMOVE CASE COVER

(a) Remove the 5 bolts.
HINT:
Apply sealant to the bolt threads.
LOCTITE 242 or equivalent
D02753 (b) Using a brass bar and hammer, tap the case cover and
remove it.

TR−19
FIPG HINT:
Apply FIPG to the rear case.
5 mm (0.20 in.) FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
D02754
16. SEPARATE FRONT CASE AND REAR CASE

(a) Using a snap ring expander, remove the snap ring from
the rear case.
(b) Remove the 8 bolts.
HINT:
Apply sealant to the ”A” bolt threads.
A
D02755 LOCTITE 242 or equivalent
(c) Using a brass bar and hammer, tap the rear case and sep-
arate it.
HINT:
FIPG 3 mm (0.12 in.) At the time of reassembly, please refer to the following item.
Apply FIPG to the front case.
equivalent
17. REMOVE 2 BEARING OUTER RACES FROM REAR
CASE
D02756
18. REMOVE OIL RECEIVER PIPE

Remove the 2 bolts and oil receiver pipes from the rear case.
B
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 18 N·m (185 kgf·cm, 13 ft·lbf)
19. REMOVE INPUT SHAFT ASSEMBLY FROM FRONT
CASE
A
D02757

TR−20

REMOVE IDLER GEAR ASSEMBLY, OUTPUT SHAFT
ASSEMBLY, NO.1 SHIFT FORK WITH HIGH AND LOW
SHIFT FORK SHAFT
(a) Remove the idler gear assembly, output shaft assembly,
No.1 shift fork with the high and low shift fork shaft from
the front case.
NOTICE:
TF1082 At the time of reassembly, please refer to the following
item.
Set the shift inner lever into the fork head part of the No.1
shift fork securely.
(b) Using a pin punch and hammer, drive out the slotted
spring pin from the No.1 shift fork.
(c) Separate the No.1 shift fork and the high and low shift fork
shaft.
REMOVE IDLER GEAR ASSEMBLY FROM FRONT
CASE
HINT:
TF1092 If it is difficult to remove and install the idler gear assembly, pull
up the output shaft assembly.
REMOVE SHIFT OUTER LEVER AND SHIFT INNER
LEVER SHAFT
(a) Remove the nut and washer from the shift outer lever.
D02819
(b) Using a pin punch and hammer, drive out the lever lock
pin.
(c) Remove the shift outer lever and shift inner lever shaft.
D02820

TR−21

REMOVE SHIFT OUTER LEVER
D02758
pin.
(c) Remove the shift outer lever from the shift inner lever.
D02759

REMOVE NO.1 SHIFT FORK AND HIGH AND LOW
SHIFT FORK SHAFT
(a) Using a pin punch and hammer, drive out the slotted
spring pin from the No.1 shift fork.
(b) Remove the No.1 shift fork and the high and low shift fork
shaft.
NOTICE:
D02760 At the time of reassembly, please refer to the following
item.
Set the shift inner lever into the fork head part of the No.1
REMOVE OUTPUT SHAFT ASSEMBLY FROM FRONT
CASE

REMOVE FRONT DRIVE SHIFT FORK SHAFT
(a) Remove the front drive shift fork shaft from the front case.
NOTICE:
At the time of reassembly, please refer to the following
items.
S Set the shift inner lever into the fork head part of the
front drive shift fork shaft securely.
D02761

TR−22
S After installing the front drive shift fork shaft, push

Straight Pin
the straight pin in the groove of the front drive shift
fork shaft, as shown in the illustration.
Front Drive Shift

Push Fork Shaft D02762
(b) Using 2 screwdrivers and a hammer, drive out the snap

ring from the front drive shift fork shaft.
D02763

REMOVE SHIFT INNER LEVER SHAFT AND SHIFT IN-
NER LEVER
(a) Remove the shift inner lever shaft and shift inner lever
from the front case.
(b) Using a screwdriver, pry out the E−ring and separate the
shift inner lever shaft and shift inner lever.
D02765

REMOVE STRAIGHT PIN
Using a magnetic finger, remove the straight pin from the front
case.
D02764
29. IF NECESSARY, REPLACE SHIFT LEVER OIL SEAL

OF FRONT CASE
(a) Using a screwdriver, pry out the oil seal.
(b) Apply MP grease to the lip of a new oil seal.
SST (c) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00270), 09950−70010
(09951−07150)
D02766

TR−23
30. IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL

OF FRONT CASE
(a) Using SST and a hammer, drive out the oil seal.
SST 09316−60011 (09316−00011)
SST (b) Apply MP grease to the lip of a new oil seal.
D02767
(c) Using SST and a hammer, drive in a new oil seal.

SST 09316−60011 (09316−00011, 09316−00031)
SST
D02768
31. REMOVE OIL RECEIVER

Remove the bolt and oil receiver from the front case.
D02769
32. IF NECESSARY, REPLACE BEARING OUTER RACE

OF FRONT CASE
(a) Using SST, remove the bearing outer race (for the idler
gear).
SST 09950−40011 (09951−04020, 09952−04010,
SST 09953−04030, 09954−04010, 09955−04060,
09957−04010), 09950−60010 (09951−00320)
D02770
HINT:
Using SST and a press, install the bearing outer race (for the
idler gear).
SST 09316−60011 (09316−00011, 09316−00031),
SST 09950−60020 (09951−00790)
D02661

TR−24
(b) Using a brass bar and hammer, remove the bearing outer
race (for the output shaft).
TF0867
HINT:
Using SST and a press, install the bearing outer race (for the
SST output shaft).
SST 09316−60011 (09316−00011, 09316−00031),
09950−60020 (09951−00890)
D02662
33. INSPECT TRANSFER INDICATOR SWITCH

Check that continuity exists between the terminals, as shown.
Switch Position Specified Condition
Push Continuity
Free No continuity
If continuity is not as specified, replace the switch.
Push
Free
D02689
34. INSPECT NO.2 SHIFT FORK AND FRONT DRIVE

CLUTCH SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the No.2
shift fork and clutch sleeve.
Standard clearance: 0.1 − 0.4 mm (0.0039 − 0.0157 in.)
Maximum clearance: 0.4 mm (0.0157 in.)
If the clearance exceeds the maximum, replace the shift fork or
clutch sleeve.
WM0066

TR−3
TR08Y−01
DISASSEMBLY
1. REMOVE BREATHER HOSE
2. REMOVE SPEED SENSOR DRIVEN GEAR
Remove the bolt and speed sensor driven gear.
3. REMOVE SCREW PLUG, SPRING AND BALL

(a) Using a torx socket wrench (T40), remove the 4 screw
plugs.
(b) Using a magnetic finger, remove the 2 springs and balls.
4. REMOVE TRANSFER INDICATOR SWITCH
Remove the transfer 4WD position switch, L4 position switch,
neutral position switch and 3 gaskets.
D01985
5. REMOVE OUTPUT SHAFT COMPANION FLANGE

(a) Using a chisel and hammer, unstake the staked part of the
nut.
D01986
(b) Using SST to hold the flange, remove the nut and O−ring.
SST 09330−00021
(c) Remove the companion flange.
SST D01987
(d) Remove the speed sensor drive gear from the companion
flange.
D04829

TR−4
(e) Using SST, remove the dust deflector from the companion
flange.
SST 09950−40011 (09951−04020, 09952−04010,
09953−04030, 09954−04010, 09955−04061,
09957−04010, 09958−04011), 09950−60010
SST (09951−00400)
D01989
6. REMOVE FRONT EXTENSION HOUSING

Remove the 6 bolts and front extension housing.
HINT:
If necessary, tap the front extension housing lightly with a plas-
tic hammer.
D01990
7. REMOVE FRONT DRIVE CLUTCH SLEEVE AND NO. 2

SHIFT FORK
(a) Using 2 screwdrivers and a hammer, tap out the snap ring
from the front drive shift fork shaft.
D01992
(b) Remove the front drive clutch sleeve, No. 2 shift fork, 2
plate washers and compression spring.
D04828
8. REMOVE NO. 2 SYNCHRONIZER OUTER RING, NO. 2

SYNCHRONIZER MIDDLE RING AND NO. 2 SYN-
CHRONIZER INNER RING
D04821

TR−5
9. REMOVE FRONT DRIVE GEAR PIECE

(a) Using a snap ring expander, remove the snap ring.
(b) Using SST, remove the front drive gear piece.
SST 09950−40011 (09951−04020, 09952−04010,
SST 09953−04030, 09954−04010, 09955−04021),
09950−60010 (09951−00290)
D04822
10. REMOVE REAR EXTENSION HOUSING

Remove the 9 bolts and rear extension housing.
HINT:
If necessary, tap the rear extension housing lightly with a plastic
hammer.
D01994
11. REMOVE SPACER FROM OUTPUT SHAFT
D01996
12. REMOVE ADJUSTING SHIM FOR IDLER GEAR TA-

PER ROLLER BEARING
D02790
13. REMOVE ADJUSTING SHIM FOR OUTPUT SHAFT TA-

PER ROLLER BEARING
D02791

TR−6
14. REMOVE CASE COVER

(a) Remove the 5 bolts.
(b) Using a brass bar and hammer, tap the case cover and
remove it.
D02753
15. SEPARATE FRONT CASE AND REAR CASE

(a) Using a snap ring expander, remove the snap ring of the
input shaft.
(b) Remove the 8 bolts.
(c) Using a brass bar and hammer, tap the rear case and sep-
arate it.
16. REMOVE 2 BEARING OUTER RACES FROM REAR
CASE
D02755

Remove the 2 bolts and oil receiver pipes from the rear case.
18. REMOVE INPUT SHAFT ASSEMBLY FROM FRONT
CASE
19. REMOVE IDLER GEAR ASSEMBLY FROM FRONT
CASE
HINT:
If it is difficult to remove the idler gear assembly, pull up the out-
D02757 put shaft assembly.
20. REMOVE SHIFT OUTER LEVER

D02758
pin.
(c) Remove the shift outer lever from the shift inner lever.
D02759

TR−7
21. REMOVE NO. 1 SHIFT FORK AND HIGH AND LOW

SHIFT FORK SHAFT
(a) Using a pin punch and hammer, drive out the slotted
spring pin from the No. 1 shift fork.
(b) Remove the No. 1 shift fork and the high and low shift fork
shaft.
22. REMOVE OUTPUT SHAFT ASSEMBLY FROM FRONT
CASE
D02760
23. REMOVE FRONT DRIVE SHIFT FORK SHAFT

(a) Remove the front drive shift fork shaft from the front case.
D02761
(b) Using 2 screwdrivers and a hammer, drive out the snap

ring from the front drive shift fork shaft.
D02763
24. REMOVE SHIFT INNER LEVER SHAFT AND SHIFT IN-

NER LEVER
(a) Remove the shift inner lever shaft and shift inner lever
from the front case.
(b) Using a screwdriver, pry out the E−ring and separate the
shift inner lever shaft and shift inner lever.
D02765
25. REMOVE STRAIGHT PIN

Using a magnetic finger, remove the straight pin from the front
case.
D02764

TR−8
26. IF NECESSARY, REPLACE SHIFT LEVER OIL SEAL

OF FRONT CASE
(a) Using a screwdriver, pry out the oil seal.
(b) Apply MP grease to the lip of a new oil seal.
SST (c) Using SST and a hammer, drive in a new oil seal.
SST 09950−60010 (09951−00270), 09950−70010
(09951−07150)
D02766
27. IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL

OF FRONT CASE
(a) Using SST and a hammer, drive out the oil seal.
SST 09316−60011 (09316−00011)
SST (b) Apply MP grease to the lip of a new oil seal.
D02767
(c) Using SST and a hammer, drive in a new oil seal.

SST 09316−60011 (09316−00011, 09316−00031)
SST
D02768

Remove the bolt and oil receiver from the front case.
D02769
29. IF NECESSARY, REPLACE BEARING OUTER RACE

OF FRONT CASE
(a) Using SST, remove the bearing outer race (for the idler
gear).
SST 09950−40011 (09951−04020, 09952−04010,
SST 09953−04030, 09954−04010, 09955−04061,
09957−04010), 09950−60010 (09951−00320)
D02770

TR−9
(b) Using SST and a press, install the bearing outer race (for
the idler gear).
SST 09316−60011 (09316−00011, 09316−00031),
09950−60020 (09951−00790)
SST
D02661
(c) Using a brass bar and hammer, remove the bearing outer
race (for the output shaft).
TF0867
(d) Using SST and a press, install the bearing outer race (for
the output shaft).
SST 09316−60011 (09316−00011, 09316−00031),
SST 09950−60020 (09951−00890)
D02662

TR−25
TR05K−01
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page TR−13).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.

TR−12
TR090−01
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL OIL RECEIVER

Install the oil receiver to the front case with the bolt.
D02769
2. INSTALL STARTING PIN

Using a magnetic finger, install the straight pin to the front case.
3. INSTALL SHIFT INNER LEVER AND SHIFT INNER LE-
VER SHAFT
(a) Assemble the shift inner lever and the shift inner lever
shaft with the E−ring.
(b) Install the shift inner lever and shift inner lever shaft to the
front case.
D02764 4. INSTALL FRONT DRIVE SHIFT FORK SHAFT
(a) Using pliers, install the snap ring to the front drive shift fork
shaft.
(b) Install the front drive shift fork shaft to the front case.
NOTICE:
S Set the shift inner lever into the fork head part of the
front drive shift fork shaft securely.
D02761

TR−13
S After installing the front drive shift fork shaft, push

Straight Pin
the straight pin in the groove of the front drive shift
fork shaft, as shown in the illustration.
5. INSTALL OUTPUT SHAFT ASSEMBLY TO FRONT
CASE
Front Drive Shift

Push Fork Shaft D02762
6. INSTALL NO. 1 SHIFT FORK AND HIGH AND LOW

SHIFT FORK SHAFT
(a) Install the No. 1 shift fork and the high and low shift fork
shaft.
NOTICE:
Set the shift inner lever into the fork head part of the No. 1
(b) Using a pin punch and hammer, drive in the slotted spring
D02760 pin to the No. 1 shift fork.
7. INSTALL SHIFT OUTER LEVER

(a) Install the shift outer lever to the shift inner lever.
(b) Using a pin punch and hammer, drive in the lever lock pin.
D02759
(c) Install the washer and nut.

8. INSTALL IDLER GEAR ASSEMBLY TO FRONT CASE
HINT:
If it is difficult to install the idler gear assembly, pull up the output
shaft assembly.
9. INSTALL INPUT SHAFT ASSEMBLY TO FRONT CASE
D02758
10. INSTALL OIL RECEIVER PIPE

B Install the 2 oil receiver pipes to the rear case with the 2 bolts.
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 18 N·m (185 kgf·cm, 13 ft·lbf)
11. INSTALL 2 BEARING OUTER RACES TO REAR CASE
A D02757

TR−14
12. ASSEMBLE FRONT CASE AND REAR CASE

FIPG 3 mm (0.12 in.) (a) Apply FIPG to the front case.
FIPG:
Part No. 08826−00090, THREE BOND 1280 or
equivalent
D02756
(b) Apply sealant to the ”A” bolt threads.

Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
(c) Install the rear case to the front case with the 8 bolts.
(d) Using a snap ring expander, install the snap ring to the in-
put shaft.
A D02755
FIPG 13. INSTALL CASE COVER

(a) Apply FIPG to the rear case.
FIPG:
5 mm (0.20 in.) Part No. 08826−00090, THREE BOND 1281 or
equivalent
D02754
(b) Apply sealant to the bolt threads.

Sealant:
242 or equivalent
(c) Install the case cover to the rear case with the 5 bolts.
D02753

TR−15
14. SELECT ADJUSTING SHIM FOR OUTPUT SHAFT TA-

PER ROLLER BEARING
(a) Using vernier calipers, measure the clearance of the di-
B
mension ”B”.
(b) Lightly hold down the bearing outer race in the thrust
measurement.
(c) Calculate the required thickness of the adjusting shim.
D02752 Thickness: Dimension ”B” + [0.070 − 0.034 mm
(0.0028 − 0.0013 in.)]
(d) From the following table, select a shim so that its thick-
2 0.30 (0.0118) 8 1.80 (0.0709)
3 0.45 (0.0177) 9 2.00 (0.0787)
4 1.00 (0.0394) 10 2.20 (0.0866)
5 1.20 (0.0472) 11 2.40 (0.0945)
6 1.40 (0.0551) 12 2.60 (0.1024)
7 1.60 (0.0630) 13 0.55 (0.0216)
15. INSTALL ADJUSTING SHIM FOR OUTPUT SHAFT TA-

PER ROLLER BEARING
D02791
16. SELECT ADJUSTING SHIM FOR IDLER GEAR TAPER

A
ROLLER BEARING
(a) Using vernier calipers, measure the clearance of the di-
mension ”A”.
(b) Lightly hold down the bearing outer race in the thrust
measurement.
(c) Calculate the required thickness of the adjusting shim.
D02751 Thickness: Dimension ”A” + [0.014 − 0.042 mm
(0.0006 − 0.0017 in.)]
(d) From the following table, select a shim so that its thick-
2 0.30 (0.0118) 8 3.20 (0.1260)
3 0.45 (0.0177) 9 3.40 (0.1339)
4 2.40 (0.0945) 10 3.60 (0.1417)
5 2.60 (0.1024) 11 3.80 (0.1496)
6 2.80 (0.1102) 12 4.00 (0.1575)
7 3.00 (0.1181) 13 0.55 (0.0216)
TR−16
17. INSTALL ADJUSTING SHIM FOR IDLER GEAR TAPER

ROLLER BEARING
D02790
18. INSTALL SPACER TO OUTPUT SHAFT
D01996
19. INSTALL REAR EXTENSION HOUSING

3 mm (0.12 in.) (a) Apply FIPG to the rear extension housing.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or
equivalent
FIPG
D01995
(b) Install the rear extension housing with the 9 bolts.

D01994

TR−17
20. INSTALL FRONT DRIVE GEAR PIECE

(a) Using SST and a press, install the front drive gear piece
to the output shaft.
SST 09517−12010, 09631−20081
SST
(b) Select a snap ring that allows the minimum axial play.
A 2.00 (0.0787) D 2.30 (0.0906)
B 2.10 (0.0827) E 2.40 (0.0945)
D04823
C 2.20 (0.0866) − −
(c) Using a snap ring expander, install a new snap ring.
21. INSTALL NO. 2 SYNCHRONIZER INNER RING, NO. 2

CHRONIZER OUTER RING
D04821
22. INSTALL FRONT DRIVE CLUTCH SLEEVE AND NO. 2

SHIFT FORK
(a) Install the front drive clutch sleeve, compression spring,
Front 2 plate washers and No. 2 shift fork.
HINT:
direction.
NOTICE:
D04825 Assemble the front drive clutch sleeve and No. 2 synchro-
nizer outer ring securely to ensure they are in the position
as shown in the illustration.
(b) Using pliers, install the snap ring to the front drive shift fork
shaft.

TR−18
23. INSTALL FRONT EXTENSION HOUSING

FIPG (a) Apply FIPG to the front extension housing.
FIPG:
3 mm (0.12 in.) Part No. 08826−00090, THREE BOND 1281 or
equivalent
D01991
(b) Install the front extension housing with the 6 bolts.

D01990
24. INSTALL OUTPUT SHAFT COMPANION FLANGE

(a) Using SST and a press, install the dust deflector to the
companion flange.
SST 09316−20011, 09316−60011 (09316−00011)
SST
TF1087
(b) Install the speed sensor drive gear to the companion

flange.
HINT:
Align the companion flange grooves with the projections on the
speed sensor drive gear.
(c) Install the companion flange.
D04829
(d) Using SST to hold the flange, install a new O−ring and
nut.
SST 09330−00021
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
SST D01987

TR−19
(e) Using a chisel and hammer, stake the nut.

25. INSTALL TRANSFER INDICATOR SWITCH
Install 3 new gaskets, transfer 4WD position switch, L4 position
switch and neutral position switch.
D01986
26. INSTALL SCREW PLUG, SPRING AND BALL

(a) Install the 2 balls and springs.
(b) Apply sealant to the screw plug threads.
Sealant:
242 or equivalent
(c) Using a torx socket wrench (T40), install the 4 screw
plugs.
D01985 Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
27. INSTALL SPEED SENSOR DRIVEN GEAR
Install the speed sensor driven gear with the bolt.
28. INSTALL BREATHER HOSE

TR−10
TR08Z−01
INSPECTION
1. INSPECT TRANSFER INDICATOR SWITCH
Check that continuity exists between the terminals, as shown.
Switch Position Specified Condition
Push Continuity
Free No continuity
Push
If continuity is not as specified, replace the switch.
Free
D02689
2. INSPECT NO. 2 SHIFT FORK AND FRONT DRIVE

CLUTCH SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the
No. 2 shift fork and clutch sleeve.
Standard clearance: 0.1 − 0.4 mm (0.0039 − 0.0157 in.)
If the clearance exceeds the maximum, replace the shift fork or
clutch sleeve.
WM0066
3. INSPECT NO. 2 SYNCHRONIZER OUTER RING, NO. 2

CHRONIZER INNER RING
(a) Check for wear or damage.
(b) Install the No. 2 synchronizer inner ring, middle ring and
outer ring to each gear.
D04821
(c) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
MT0780

TR−11
(d) Using a feeler gauge, measure the clearance between

the synchronizer ring back and gear spline end.
Standard clearance:
1.02 − 1.98 mm (0.0402 − 0.0780 in.)
Minimum clearance: 1.02 mm (0.0402 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
WM0065 NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.

TR−26
TRANSFER (Part−Time 4WD Type) − OUTPUT SHAFT
OUTPUT SHAFT
TR05R−01
COMPONENTS
Output Shaft
Needle Roller Bearing

M/T:
Synchronizer Ring
Front Taper Roller
Bearing
Front Drive Gear
Piece
Spacer
High Speed Gear Needle Roller Bearing
z Snap Ring
Clutch Hub
Rear Taper Roller

Bearing
Low Speed Gear
z Snap Ring
High and Low Hub Sleeve

M/T:
Shifting Key Spring
M/T:
Shifting Key
D02779

TR−20
OUTPUT SHAFT
TR091−01
COMPONENTS
Output Shaft
Needle Roller Bearing

M/T:
Synchronizer Ring
Front Taper Roller
Bearing
Spacer
High Speed Gear Needle Roller Bearing
M/T:
Shifting Key Spring
Clutch Hub
Rear Taper Roller

Bearing
Low Speed Gear
z Snap Ring
High and Low Hub Sleeve

M/T:
Shifting Key Spring
M/T:
Shifting Key
D04830

TR−27
TR05S−01
DISASSEMBLY
1. MEASURE EACH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance of the high
speed gear and low speed gear.
High speed gear:
Standard clearance:
0.28 − 0.43 mm (0.0110 − 0.0169 in.)
TF1074
Low speed gear:
Standard clearance:
0.20 − 0.45 mm (0.0079 − 0.0177 in.)
2. MEASURE EACH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance of the high
Standard clearance:
0.015 − 0.068 mm (0.0005 − 0.0027 in.)
TF1075
3. REMOVE FRONT DRIVE GEAR PIECE

Socket Wrench SST (b) Using SST, a socket wrench and press, remove the front
drive gear piece.
SST 09950−00020
NOTICE:
Support the output shaft assembly by hand so that it will
not be dropped off.
D02788
4. REMOVE FRONT TAPER ROLLER BEARING

Using SST and a press, remove the front taper roller bearing.
SST 09950−00020
NOTICE:
SST S Support the output shaft assembly by hand so that it
will not be dropped off.
S Set the claw of SST to the bearing inner race securely.
5. REMOVE HIGH SPEED GEAR, SYNCHRONIZER RING
TF1048 (M/T), NEEDLE ROLLER BEARING AND SPACER

TR−28
6. REMOVE LOW SPEED GEAR AND REAR TAPER

ROLLER BEARING
(a) Using a press, remove the low speed gear and rear taper
roller bearing.
(b) Remove the needle roller bearing.
TF1051
7. REMOVE HIGH AND LOW HUB SLEEVE

(a) Remove the high and low hub sleeve.
(b) M/T:
Using a screwdriver, remove the 2 shifting key springs.
(c) M/T:
Remove the 3 shifting keys from the clutch hub.
D02780
8. REMOVE CLUTCH HUB

(a) Using 2 screwdrivers and a hammer, drive out the snap
ring.
D02789
(b) Using a press, remove the clutch hub.
TF1022

TR−21
TR092−01
DISASSEMBLY
1. MEASURE EACH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance of the high
High speed gear
Standard clearance:
0.28 − 0.43 mm (0.0110 − 0.0169 in.)
D04831
Low speed gear
Standard clearance:
0.20 − 0.45 mm (0.0079 − 0.0177 in.)
2. MEASURE EACH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance of the high
Standard clearance:
0.015 − 0.068 mm (0.0005 − 0.0027 in.)
D04832

Using SST and a press, remove the front taper roller bearing.
SST 09950−00020
NOTICE:
SST S Support the output shaft assembly by hand so that it
will not be dropped off.
S Set the claw of SST to the bearing inner race securely.
4. REMOVE HIGH SPEED GEAR, SYNCHRONIZER RING
TF1048 (M/T), NEEDLE ROLLER BEARING AND SPACER
5. REMOVE REAR TAPER ROLLER BEARING AND LOW

SPEED GEAR
(a) Using a press, remove the rear taper roller bearing and
low speed gear.
(b) Remove the needle roller bearing.
TF1051

TR−22
6. REMOVE HIGH AND LOW HUB SLEEVE

(a) Remove the high and low hub sleeve.
(b) M/T:
Using a screwdriver, remove the 2 shifting key springs.
(c) M/T:
Remove the 3 shifting keys from the clutch hub.
D02780
7. REMOVE CLUTCH HUB

(a) Using 2 screwdrivers and a hammer, drive out the snap
ring.
D02789
(b) Using a press, remove the clutch hub.
TF1022

TR−29
TR05T−01
INSPECTION
B A 1. INSPECT OUTPUT SHAFT
(a) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
High speed gear A: 41.984 mm (1.6529 in.)
Low speed gear B: 42.984 mm (1.6923 in.)
If the diameter is less than the minimum, replace the output
D02781
shaft.
(b) Using vernier calipers, measure the length of the output

shaft journal.
B A Maximum length:
High speed gear A: 51.55 mm (2.0295 in.)
Low speed gear B: 62.35 mm (2.4547 in.)
If the length exceeds the maximum, replace the output shaft.
D02782
2. M/T:
INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
WM0064 cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.

TR−30
(d) Using a feeler gauge, measure the clearance between

the synchronizer ring back and gear spline end.
Standard clearance:
0.68 − 1.66 mm (0.0268 − 0.0654 in.)
Minimum clearance: 0.68 mm (0.0268 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
WM0065 NOTICE:
off after rubbing.
3. MEASURE SHIFT FORK AND HUB SLEEVE CLEAR-

ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Standard clearance:
0.1 − 0.4 mm (0.0039 − 0.0157 in.)
Maximum clearance:
0.4 mm (0.0157 in.)
WM0066 If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.

TR−31
TR05U−02
REASSEMBLY
HINT:
reassembly.
1. INSTALL CLUTCH HUB INTO HIGH AND LOW HUB
Front SLEEVE
(a) Install the clutch hub and shifting keys to the high and low
hub sleeve.
TF1102
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not
aligned.
2. INSTALL HIGH AND LOW HUB SLEEVE ASSEMBLY

(a) Using SST and a press, install the high and low hub
sleeve assembly.
SST 09316−20011
SST
TF1018
A 2.60 (0.1024) E 2.80 (0.1102)
B 2.65 (0.1043) F 2.85 (0.1122)
C 2.70 (0.1063) G 2.90 (0.1142)
D 2.75 (0.1083) − −
TF1021
3. INSTALL NEEDLE ROLLER BEARING, LOW SPEED

GEAR AND REAR TAPER ROLLER BEARING
SST (a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing and low speed gear.
(c) Using SST and a press, install the rear taper roller bear-
ing.
SST 09316−60011 (09316−00011)
TF1047

TR−32
4. INSTALL NEEDLE ROLLER BEARING, SPACER, SYN-

CHRONIZER RING (M/T) AND HIGH SPEED GEAR
(a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing, spacer, synchronizer ring
(M/T) and high speed gear.
NOTICE:
M/T:
Align the ring slots with the shifting keys.
5. INSTALL FRONT TAPER ROLLER BEARING

Using SST and a press, install the front taper roller bearing.
SST SST 09316−60011 (09316−00011)
TF1029
6. INSTALL FRONT DRIVE GEAR PIECE

(a) Using SST and a press, install the front drive gear piece.
SST 09316−60011 (09316−00031)
SST
TF1031
A 2.00 (0.0787) D 2.30 (0.0906)
B 2.10 (0.0827) E 2.40 (0.0945)
C 2.20 (0.0866) − −
TF1030

TR−23
TR093−01
REASSEMBLY
HINT:
reassembly.
1. A/T:
INSTALL CLUTCH HUB INTO HIGH AND LOW HUB
SLEEVE
2. M/T:
INSTALL CLUTCH HUB INTO HIGH AND LOW HUB
SLEEVE
(a) Install the clutch hub and 3 shifting keys to the high and
low hub sleeve.
Front (b) Install the 2 shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not
TF1102 aligned.
3. INSTALL HIGH AND LOW HUB SLEEVE ASSEMBLY

(a) Using SST and a press, install the high and low hub
sleeve assembly to the output shaft.
SST 09316−20011
SST
TF1018
A 2.60 (0.1024) E 2.80 (0.1102)
B 2.65 (0.1043) F 2.85 (0.1122)
C 2.70 (0.1063) G 2.90 (0.1142)
D 2.75 (0.1083) − −
TF1021
4. INSTALL NEEDLE ROLLER BEARING, LOW SPEED

GEAR AND REAR TAPER ROLLER BEARING
SST (a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing and low speed gear.
(c) Using SST and a press, install the rear taper roller bear-
ing.
SST 09316−60011 (09316−00011)
TF1047

TR−24
5. INSTALL SPACER, NEEDLE ROLLER BEARING, SYN-

CHRONIZER RING (M/T) AND HIGH SPEED GEAR
(a) Apply gear oil to the needle roller bearing.
(b) Install the spacer, needle roller bearing, synchronizer ring
(M/T) and high speed gear.
NOTICE:
M/T:
Align the ring slots with the shifting keys.

SST SST 09316−60011 (09316−00011)
TF1029

TR−33
TRANSFER (Part−Time 4WD Type) − INPUT SHAFT
INPUT SHAFT
TR05L−01
COMPONENTS
z Snap Ring
Input Shaft
z Front Ball Bearing
Rear Ball Bearing

z Snap Ring
D02654

TR−34
TR05M−01
DISASSEMBLY
1. REMOVE REAR BALL BEARING
D02691
(b) Using a socket wrench and press, remove the rear ball
bearing.
Socket Wrench
D02853
2. REMOVE FRONT BALL BEARING

(b) Using SST, remove the front ball bearing.
SST 09950−40011 (09951−04020, 09952−04010,
SST 09953−04030, 09954−04010, 09955−04010,
09957−04010, 09958−04010), 09950−60010
(09951−00400)
D02655

TR−35
TR05N−01
REASSEMBLY
HINT:
SST reassembly.
1. INSTALL FRONT BALL BEARING
(a) Using SST and a press, install a new front ball bearing.
SST 09316−60011 (09316−00011)
D02656
(b) Select a snap ring that will allow the minimum axial play.
A 2.90 (0.1141) D 3.05 (0.1201)
B 2.95 (0.1161) E 3.10 (0.1220)
C 3.00 (0.1181) F 3.15 (0.1240)
D02657
2. INSTALL REAR BALL BEARING

(a) Using SST and a press, install the rear ball bearing.
SST 09316−60011 (09316−00011, 09316−00031)
SST
D02658
(b) Select a snap ring that will allow the minimum axial play.
Mark Thickness mm (in.)
A 2.00 (0.0787)
B 2.10 (0.0827)
C 2.20 (0.0866)
D 2.30 (0.0906)
E 2.40 (0.0945)
D02659

TR−36
TRANSFER (Part−Time 4WD Type) − IDLER GEAR
IDLER GEAR
TR05O−01
COMPONENTS
Rear Taper Roller Bearing

Idler Gear
Oil Receiver
7.8 (80, 69)

Front Taper Roller Bearing
N·m (kgf·cm, in.·lbf) : Specified torque

D02771

TR−37
TR05P−01
Socket Wrench DISASSEMBLY

1. REMOVE REAR TAPER ROLLER BEARING
SST
Using SST, a press and socket wrench, remove the rear taper
roller bearing.
SST 09950−00020
NOTICE:
Set the claw of SST to the bearing inner race securely.
D02772

Using SST and a socket wrench, remove the front taper roller
bearing.
Socket Wrench SST 09950−40011 (09951−04020, 09952−04010,
SST 09953−04030, 09954−04030, 09955−04060,
09957−04010, 09958−04010), 09950−60010
(09951−00300)
NOTICE:
D02773 Set the claw of SST to the bearing inner race securely.

Remove the 3 bolts and oil receiver.
D02774

TR−38
TR05Q−01
REASSEMBLY
HINT:
reassembly.
1. INSTALL OIL RECEIVER
(a) Install the oil receiver.
(b) Install and torque the 3 bolts.
D02774

SST 09316−60011 (09316−00011, 09316−00051)
SST
D02775
3. INSTALL REAR TAPER ROLLER BEARING

Using SST and a press, install the rear taper roller bearing.
SST SST 09350−32014 (09351−32120, 09351−32140,
09351−32180)
D02776

TR−39
TRANSFER (Part−Time 4WD Type) − FRONT EXTENSION HOUSING
FRONT EXTENSION HOUSING

TR05V−01
COMPONENTS
4.9 (50, 43)
Drive Clutch Hub
z Snap Ring
Oil Receiver Pipe
Dust Deflector
z Snap Ring
Ball Bearing
z Oil Seal
Front Extension Housing
Front Output Shaft


TR−25
FRONT EXTENSION HOUSING

TR094−01
COMPONENTS
4.9 (50, 43) No. 1 Synchromesh Shifting Key
Drive Clutch Hub

Key Spring
z Shifting Key Retainer z Snap Ring
z Snap Ring
Oil Receiver Pipe
Key Spring
Dust Deflector
Key Spring
Ball Bearing No. 1 Synchromesh

Shifting Key
No. 1 Synchromesh
z Oil Seal
Shifting Key
Front Extension Housing
Front Output Shaft


TR−40
TR05W−01
DISASSEMBLY
Remove the 2 bolts and oil receiver pipe.
D02784
2. REMOVE DRIVE CLUTCH HUB

(b) Using SST, remove the drive clutch hub.
SST 09950−40011 (09951−04020, 09952−04010,
SST 09953−04030, 09954−04010, 09955−04020)
3. REMOVE FRONT OUTPUT SHAFT
Using a plastic hammer, tap the front output shaft and remove
it.
D02785
4. REMOVE DUST DEFLECTOR

SST (a) Using SST, remove the dust deflector from the front out-
put shaft.
SST 09950−40011 (09951−04020, 09952−04010,
09953−04030, 09954−04010, 09955−04050,
09958−04010)
D02786
(b) Using a screwdriver and hammer, tap the dust deflector

from the front extension housing and remove it.
5. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal from the front extension
housing.
TF0937
6. REMOVE BALL BEARING

(a) Using a screwdriver, remove the snap ring from the front
extension housing.
(b) Using SST and a press, remove the ball bearing.
SST
SST 09316−60011 (09316−00011, 09316−00071)
TF0940

TR−26
TR095−01
DISASSEMBLY
Remove the 2 bolts and oil receiver pipe.
D02784
2. REMOVE DRIVE CLUTCH HUB

(b) Using SST, remove the drive clutch hub.
SST 09950−40011 (09951−04020, 09952−04010,
SST 09953−04030, 09954−04010, 09955−04021)
D02785
(c) Remove the 3 No. 1 synchromesh shifting keys and

springs from the drive clutch hub.
D04813
(d) Mount the drive clutch hub in a vise.

(e) Using a screwdriver and hammer, tap the shifting key re-
tainer from the drive clutch hub and remove it.
3. REMOVE FRONT OUTPUT SHAFT
Using a plastic hammer, tap the front output shaft and remove
it.
D04814
4. REMOVE DUST DEFLECTOR

SST (a) Using SST, remove the dust deflector from the front out-
put shaft.
SST 09950−40011 (09951−04020, 09952−04010,
09953−04030, 09954−04010, 09955−04051,
09957−04010)
D02786

TR−27
(b) Using a screwdriver and hammer, tap the dust deflector

from the front extension housing and remove it.
5. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal from the front extension
housing.
TF0937
6. REMOVE BALL BEARING

(a) Using a screwdriver, remove the snap ring from the front
extension housing.
TF0939
(b) Using SST and a press, remove the ball bearing.

SST 09316−60011 (09316−00011, 09316−00071)
SST
TF0940

TR−41
TR05X−01
REASSEMBLY
HINT:
reassembly.
1. INSTALL DUST DEFLECTOR
(a) Using a plastic hammer, install the dust deflector to the
front extension housing.
(b) Using SST and a press, install the dust deflector to the
front output shaft.
SST 09316−20011, 09316−60011 (09316−00011)
SST
TF0967
2. INSTALL BALL BEARING

(a) Using SST and a press, install the ball bearing.
SST 09316−60011 (09316−00011, 09316−00031)
SST
TF0943
A 1.70 (0.0669)
B 1.80 (0.0709)
(c) Using a screwdriver, install a new snap ring.
TF0939
3. INSTALL OIL SEAL

(a) Apply MP grease to the lip of a new oil seal.
(b) Using SST and a hammer, drive in a new oil seal to the
SST 09316−60011 (09316−00011, 09316−00061)
SST
TF0945

TR−42
4. INSTALL FRONT OUTPUT SHAFT AND DRIVE

CLUTCH HUB
(a) Using SST and a press, install the front output shaft and
SST drive clutch hub.
SST 09316−20011, 09316−60011 (09316−00011,
09316−00051, 09316−00071)
D02787
A 1.80 (0.0709) D 2.10 (0.0827)
B 1.90 (0.0748) E 2.20 (0.0866)
C 2.00 (0.0787) − −
TF1035

(a) Install the oil receiver pipe to the front extension housing.
(b) Install and torque the 2 bolts.
D02784

TR−28
TR096−01
REASSEMBLY
HINT:
reassembly.
1. INSTALL DUST DEFLECTOR
(a) Using a plastic hammer, install the dust deflector to the
(b) Using SST and a press, install the dust deflector to the
front output shaft.
SST 09316−20011, 09316−60011 (09316−00011)
SST
TF0967
2. INSTALL BALL BEARING

(a) Using SST and a press, install the ball bearing.
SST SST 09316−60011 (09316−00011, 09316−00031)
Sealed Side
NOTICE:
As shown in the illustration, assemble the ball bearing pay-
ing attention to the sealing direction.
D04815
A 1.70 (0.0669)
B 1.80 (0.0709)
(c) Using a screwdriver, install a new snap ring.
TF0939
3. INSTALL OIL SEAL

(b) Using SST and a hammer, drive in a new oil seal to the
SST 09316−60011 (09316−00011, 09316−00061)
SST
TF0945

TR−29
4. INSTALL FRONT OUTPUT SHAFT

Using SST and a press, install the front output shaft.
SST 09309−60010, 09316−60011 (09316−00011)
SST
SST
D04816
5. INSTALL DRIVE CLUTCH HUB

(a) Using SST and a press, install a new shifting key retainer
to the drive clutch hub.
SST
SST 09649−17010
D04817
(b) Install the 3 key springs and No. 1 synchromesh shifting

keys to the drive clutch hub.
D04813
(c) Using SST and a press, install the drive clutch hub as-
sembly to the front output shaft.
SST SST 09316−20011, 09316−60011 (09316−00011)
SST
D04818
(d) Select a snap ring that allows the minimum axial play.
A 2.00 (0.0787) D 2.30 (0.0906)
B 2.10 (0.0827) E 2.40 (0.0945)
C 2.20 (0.0866) − −
(e) Using a snap ring expander, install a new snap ring.
TF1035

TR−30

Install the oil receiver pipe to the front extension housing with
the 2 bolts.
D02784

TR−43
TRANSFER (Part−Time 4WD Type) − REAR EXTENSION HOUSING OIL SEAL
REAR EXTENSION HOUSING OIL SEAL

TR05Y−01
COMPONENTS
Rear Extension Housing
z Oil Seal

TR−44
TRANSFER (Part−Time 4WD Type) − REAR EXTENSION HOUSING OIL SEAL
TR05Z−01
REPLACEMENT
1. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal from the rear extension
housing.
2. INSTALL OIL SEAL

(b) Using SST and a hammer, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
SST
D02778

TR−45
TRANSFER (Part−Time 4WD Type) − TRANSFER SHIFT LEVER ASSEMBLY
TRANSFER SHIFT LEVER ASSEMBLY

TR060−02
COMPONENTS
w/o One Touch 2−4 Selector System, Bench Seat (M/T):
Lever Lock Pin
Transfer Shift Lever Transfer Shift Lever

Assembly
12 (120, 9)
Transfer Shift Lever Boot
Transfer Shift Lever Shaft

12 (120, 9)
Transfer
Shift Lever Boot
29 (300, 22) Wave Washer

Wave Washer
Shift Lever Cap 13 (130, 9)

Slotted Spring Pin Rod Assembly
Transfer Shift Lever Support Bushing

Wave Washer
R151F (M/T): 12 (120, 9)
19 (190, 14)
H151F (M/T):
19 (190, 14)
x6
Bushing
z Gasket
Transfer Control Shift
Lever Retainer
Compression Spring
Plate Washer Transfer Control
Snap Ring Shift Lever Retainer
z Oil Deflector Compression Spring

Plate Washer
Snap Ring
N·m (kgf·cm, ft·lbf) : Specified torque z Gasket

: MP Grease D03174

TR−46
w/ One Touch 2−4 Selector System, Bench Seat (M/T):
29 (300, 22)
Shift Lever Cap Transfer Shift Lever Shaft

Lever Lock Pin Boot
Transfer Shift 12 (120, 9) Wave Washer
Lever Assembly
Bushing Bushing Transfer Shift
Transfer Shift Lever Rod
Lever Assembly
Clip
Slotted Spring Pin Plate Washer

Wave Washer
19 (190, 14)
Wave Washer
12 (120, 9)
x6
19 (190, 14)
R151F (M/T):
Transfer Control Bushing
Shift Lever
z Gasket
Retainer
H151F (M/T):
R151F (M/T): Transfer Control
z Oil Deflector Shift Lever
Retainer
H151F (M/T):
z Gasket
: MP Grease
D03175

TR−47
Separate Seat (M/T):
Lever Lock Pin
12 (120, 9)

29 (300, 22)
Shift Lever Cap w/ One Touch 2−4 Selector System:

w/o One Touch 2−4 Transfer Shift Lever Boot

Slotted Spring Pin Selector System:
Transfer Shift Lever Bushing
Support
19 (190, 14)
Wave Washer
Bushing
z Gasket
Transfer Control Shift Transfer Shift Lever Shaft
Lever Retainer
Transfer Shift
Lever Boot
w/o One Touch 2−4 Bushing
Selector System:
Compression Spring
Plate Washer
Snap Ring
w/ One Touch 2−4 Selector System:
Transfer Shift Lever Shaft
z Gasket

: MP Grease
D03176

TR−48
LHD (A/T):
Plate Washer
Clip
Wave Washer
Bushing

Rod Assembly
29 (300, 22) 14 (140, 10)
Wiring Harness Clamp Bracket
Bushing
z Gasket Transfer Shift Lever

Boot
Snap Ring
Wave Washer
Plate Washer
Lever Retainer
z Gasket

: MP Grease D03172

TR−49
RHD (A/T):
Transfer Shift Lever Shaft Plate Washer
Wave Washer
Clip
Transfer Shift Lever Rod

Assembly
Bushing
14 (140, 10)
29 (300, 22)
Wiring Harness Clamp

Bracket
Transfer Shift
Lever Assembly Bushing
z Gasket Boot
Wave Washer
Transfer Shift
Lever Boot
Lever Retainer
Tight Plug
z Gasket
Slotted Spring Pin

: MP Grease
D03173

TR−50
TRANSFER (Part−Time 4WD Type) − ONE TOUCH 2−4 SELECTOR SYSTEM
ONE TOUCH 2−4 SELECTOR SYSTEM

TR061−01
LOCATION
2−4 Selector Switch

4WD Indicator Light
Combination Meter
4WD Control Relay
Transfer 4WD Position Switch
Motor Actuator
L4 Position Switch
D02868

TR−51
TR062−02
INSPECTION
1. INSPECT SWITCHING H2«H4 POSITION
(a) Start the engine, and shift the transfer shift lever to the
”H2” position.
ON OFF
(b) Check that the 4WD indicator light comes on when the
switch is in ”ON” position. Check that the light goes off
when the switch is in ”OFF” position.
D03204
2. INSPECT SWITCHING H2«L4 POSITION

(a) Start the engine, and push the 2−4 selector switch to OFF.
(b) Check that the 4WD indicator light comes on when the
transfer shift lever is shifted to the ”L4” position. Check
that the light goes off when the lever is shifted to the ”N”
or ”H2” position.
D03205
Relay Side: 3. INSPECT 4WD CONTROL RELAY

(a) Check that continuity exists between each terminal, as
shown in the table.
Tester connection Specified condition
1−2 Continuity
2−4 Continuity
6−7 *
*: There is a diode between the terminals 6 and 7.
Z15367
If no continuity exists, check that continuity exists when chang-
ing the position of probe for the position of negative prove
of tester.
(b) Apply battery voltage between each terminal and check
that continuity exists between each terminal, as shown in
the table.
Battery voltage
Tester connection Specified condition
applied terminal
1−3 Continuity
6 (+) − 5 (−)
1−2 No continuity
7 (+) − 2 (−) 9 − 10 No continuity
3−4 Continuity
9 (+) − 10 (−)
2−4 No continuity
If continuity is not as specified, replace the relay.

TR−52
4. INSPECT ACTUATOR OPERATION

2WD ® 4WD (a) Raise up the front wheels, place the stopper under the
2
4
rear wheels to block them, and pull up the parking brake.
5
1 3
(b) Disconnect the connector of the actuator and connect it
to the relay using wire.
(c) Check that the front propeller shaft can be rotated by
54321 hand.
Inspection item Standard
2WD ® 4WD Front propeller shaft cannot be rotated
4WD ® 2WD Front propeller shaft can be rotated
4WD ® 2WD
2
4 5
1 3
5 4 3 21
D02869
HINT:
Heater Main Relay:
2 1 When inspecting the operation described above, use a heater
3
main relay.
2
4 5
1 3
5 4
F02596
Motor Actuator Side: 5. INSPECT MOTOR ACTUATOR (MOTOR)

(a) Remove the motor actuator (See page TR−13).
(b) Measure the resistance between the terminals 1 and 5.
Standard resistance: 0.3 − 100 W
(c) Measure the resistance between the terminals 1 or 5 and
body ground.
Standard resistance: More than 0.5 MW
If the resistance value is not as specified, replace the motor ac-
D02663 tuator.

TR−53
6. INSPECT 2−4 SELECTOR SWITCH CONTINUITY

(a) Remove the 2−4 selector switch (See page AC−177).
(b) Inspect the continuity between each terminal.
2−4 selector switch
3 Tester connection Specified condition
condition
2 1−2 No continuity
ON (4WD) 1−3 No continuity
1
2−3 Continuity
D03212 1−2 Continuity

OFF (2WD) 1−3 No continuity
2−3 No continuity
7. I NSPECT L 4 AND TRANSFER 4 W D PO SI TI O N

Ball
SWITCH CONTINUITY
(a) Remove the L4 and transfer 4WD position switch (See
page TR−13).
(b) Check that continuity exists between terminals 1 and 2
27±0.82mm when pushing the ball at the tip of the switch.
ON−OFF
D02665

105 Series Overhaul - HF1A

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TR−1

TRANSFER (Part−Time 4WD Type) − TRANSFER SYSTEM

LAND CRUISER (W/G) (RM616E)

PROBLEM SYMPTOMS TABLE

1. Oil (Level too high) TR−6

1. Transfer shift lever assembly (Faulty) TR−45

1. Locking ball spring (Damaged) TR−11

LAND CRUISER (W/G) (RM616E)

PROBLEM SYMPTOMS TABLE

1. Oil (Level too high) *

1. Transfer shift lever assembly (Faulty) *

1. Locking ball spring (Damaged) TR−2

*: See Pub. No. RM616E

LAND CRUISER SUP (RM695E)

Front Console Box

Transfer Shift Lever Assembly

Shift Lever Boot

Neutral Position Switch

12 (120, 9) Breather Hose

N·m (kgf·cm, ft·lbf) : Specified torque

LAND CRUISER (W/G) (RM616E)

w/ One Touch 2−4 Selector System (M/T):

Front Console Box

Shift Lever Boot

Front Propeller Shaft

N·m (kgf·cm, ft·lbf) : Specified torque

LAND CRUISER (W/G) (RM616E)

106 (1,080, 78)

L4 Position Switch 106 (1,080, 78)

Motor Actuator Neutral Position

Transfer 4WD Position

No.1 Speed Sensor Connector

Breather Hose 69 (700, 51)

Front Propeller Shaft

N·m (kgf·cm, ft·lbf) : Specified torque

LAND CRUISER (W/G) (RM616E)

4. REMOVE TRANSFER CASE PROTECTOR

Filler Plug 5. DRAIN TRANSFER OIL

Drain Plug D02809

6. w/o One Touch 2−4 Selector System, Bench Seat

LAND CRUISER (W/G) (RM616E)

7. w/ One Touch 2−4 Selector System, Bench Seat (M/T):

LAND CRUISER (W/G) (RM616E)

Wooden Block 9. REMOVE CROSSMEMBER

11. w/ One Touch 2−4 Selector System (M/T) & A/T:

LAND CRUISER (W/G) (RM616E)

14. JACK UP TRANSFER SLIGHTLY

LAND CRUISER (W/G) (RM616E)

LAND CRUISER (W/G) (RM616E)

Separate Seat (M/T): 12 (120, 9) Lever Lock Pin

Shift Outer L 19 (190, 14)

x6 Front Drive Shift

18 (185, 13) z Gasket z Gasket x5

Input Shaft Assembly

LAND CRUISER (W/G) (RM616E)

w/ One Touch 2−4 Selector System:

Front Drive Clutch Sleeve

LAND CRUISER (W/G) (RM616E)

18 (185, 13) z Gasket z Gasket

Input Shaft Assembly

LAND CRUISER SUP (RM695E)

3. w/ One Touch 2−4 Selector System:

S Apply FIPG to the motor actuator.

5. REMOVE SCREW PLUG, SPRING AND BALL