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Transfer Case Front Oil Seal: Replacement

  1. DRAIN AUTOMATIC TRANSMISSION FLUID ( AUTOMATIC TRANSMISSION FLUID  ) 
  2. REMOVE FRONT EXHAUST PIPE ASSEMBLY ( REMOVAL  ) 
  3. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See  REMOVAL  ) 
  4. REMOVE FLANGE YOKE 
    1. Using SST and a hammer, release the staked part of the nut.

      SST 09930-00010 

      Fig 1: Releasing Staked Part Of Nut Using SST And Hammer
      G04028843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be sure to use the SST with the tapered surface facing the shaft.
      • Do not grind the tip of the SST with a grinder or other device.
      • Completely loosen the staked part of the nut when removing it.
      • Do not damage the threads of the output shaft.
    2. Using SST, hold the flange yoke.

      SST 09330-00021, 09213-54015 

    3. Using a deep socket wench (30 mm), remove the nut.
    4. Remove the flange yoke from the transfer assembly.
      Fig 2: Identifying Flange Yoke Nut From Transfer Assembly
      G04028844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSFER CASE FRONT OIL SEAL 
    1. Using SST, remove the oil seal.

      SST 09308-00010 

      Fig 3: Identifying Transfer Case Front Oil Seal Using SST
      G04028845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL TRANSFER CASE FRONT OIL SEAL 
    1. Using SST and a hammer, install a new oil seal.

      SST 09316-60011 (09316-00011, 09316-00071) 

      Fig 4: Identifying Transfer Case Front Oil Seal Using SST And Hammer
      G04028846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Oil seal drive in depth: 

      5.6 to 6.2 mm (0.220 to 0.244 in.) 

    2. Apply MP grease to the oil seal lip.
  7. INSTALL FLANGE YOKE 
    1. Install the flange yoke to the transfer assembly.
    2. Using SST, hold the flange yoke.

      SST 09213-54015, 09330-00021 

    3. Using a deep socket wench (30 mm), torque the nut.
      Fig 5: Identifying Flange Yoke Nut
      G04028847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 123 N*m (1,254 kgf*cm, 91 ft.*lbf) 

    4. Using a chisel and hammer, stake the nut.
  8. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (See  INSTALLATION  ) 
  9. INSTALL FRONT EXHAUST PIPE ASSEMBLY ( INSTALLATION  ) 
  10. ADD AUTOMATIC TRANSMISSION FLUID ( AUTOMATIC TRANSMISSION FLUID  ) 
  11. CHECK FOR EXHAUST GAS LEAKS 
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