Toyota Sequoia (2005). Manual - part 742

F19257

F19346

F19253

F19252

F19251

–

TRANSFER

TRANSFER ASSEMBLY

TR–19

2957

9.

INSTALL TRANSFER SHIFT ACTUATOR

(a)

Install the transfer shift actuator with the 3 bolts.
Torque: 20 N·m (204 kgf·cm, 15 ft·lbf)

(b)

Using a screwdriver and hammer, drive in the snap ring.

10.

INSTALL REAR NO. 2 STOPPER TRANSFER SHIFT
SHAFT

11.

INSTALL REAR OUTPUT SHAFT ASSEMBLY, GEAR
SHIFT FORK NO. 1, FRONT DRIVE CHAIN AND DRIV-
EN SPROCKET

(a)

Install the rear output shaft assembly, gear shift fork No.
1 and driven sprocket to the front drive chain.

(b)

Install the rear output shaft assembly, gear shift fork No.
1, driven sprocket and front drive chain to the transfer
case rear.

HINT:
Check that the rear output shaft and driven sprocket turn slight-
ly.

F19250

F19304

F19305

F19247

F19307

TR–20

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TRANSFER

TRANSFER ASSEMBLY

2958

(c)

Using a snap ring expander, install the snap ring.

(d)

Using a screwdriver and hammer, drive in the snap ring.

(e)

Using a screwdriver and hammer, drive in the snap ring.

12.

INSTALL FRONT NO. 2 STOPPER SHIFT SHAFT

13.

INSTALL FRONT DRIVE SHIFT FORK SHAFT

(a)

Install the 2 shift inter–lock pins.

(b)

Turn the front drive shift fork shaft, and install it on the rear
case aligning the cutout with the inter–lock pin.

14.

INSTALL SHIFT SHAFT STOPPER

Install the shift shaft stopper with the bolt.

Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)

F19308

F19306

FIPG

F19244

F19243

F19309

SST

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TRANSFER

TRANSFER ASSEMBLY

TR–21

2959

15.

INSTALL GEAR SHIFT FORK NO. 2 AND HIGH AND
LOW CLUTCH SLEEVE

(a)

Install the gear shift fork No. 2 and high and low clutch
sleeve with the bolt.
Torque: 24 N·m (245 kgf·cm, 18 ft·lbf)

(b)

Install the spacer and output shaft front needle roller bear-
ing.

16.

INSTALL TRANSFER CASE REAR

(a)

Apply FIPG to the transfer case rear, as shown.
FIPG:
Part No. 08826–00090, THREE BOND 1281 or equiva-
lent

(b)

Install the clamp and transfer case rear with the 
12 bolts.
Torque: 28 N·m (286 kgf·cm, 21 ft·lbf)

17.

INSTALL TRANSFER EXTENSION HOUSING

(a)

Install the collar and 2 transfer output washers.

(b)

Using SST and a hammer, drive in a new oil seal until its
surface is flush with the housing upper surface.
SST

09223–46011, 09631–32020

(c)

Coat the lip of the oil seal with MP grease.

F19310

FIPG

F19242

F19311

SST

F19312

Front:

Rear:

TR–22

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TRANSFER

TRANSFER ASSEMBLY

2960

(d)

Apply FIPG to the transfer extension housing, as shown.
FIPG:
Part No. 08826–00090, THREE BOND 1281 or equiva-
lent

(e)

Apply sealant to the bolt threads.
FIPG:
Part No. 08826–00080, THREE BOND 1334, LOCTITE
242 or equivalent

(f)

Install the transfer extension housing with the 5 bolts.
Torque: 12 N·m (122 kgf·cm, 9 ft·lbf)

18.

INSTALL FRONT OUTPUT SHAFT COMPANION
FLANGE

(a)

Using SST and a hammer, drive in a new oil seal.
SST

09950–60010 (09951–00320), 09950–70010
(09951–07100)

(b)

Coat the lip of the oil seal with MP grease.

(c)

Install the front output shaft companion flange to the driv-
en sprocket.

(d)

Using SST to hold the front output shaft companion
flange, install a new companion flange lock nut.
Torque: 118 N·m (1,203 kgf·cm, 87 ft·lbf)
SST

09330–00021

(e)

Using a chisel and hammer, stake the companion flange
lock nut.

19.

INSTALL REAR OUTPUT SHAFT COMPANION
FLANGE

Using SST, install the rear output shaft companion flange in the
same way as the front output shaft companion flange.

Torque: 118 N·m (1,203 kgf·cm, 87 ft·lbf)
SST

09330–00021