Toyota Sequoia (2005). Manual - part 745

TR0DJ–01

F19283

F19751

SST

Groove

F19281

F19293

F19294

–

TRANSFER

REAR OUTPUT SHAFT

TR–31

2969

REASSEMBLY

1.

INSTALL DRIVE SPROCKET

(a)

Install the output shaft plate washer and drive sprocket
bearing to the output shaft rear.

(b)

Install the drive sprocket and output shaft spacer No. 1 to
the output shaft rear.

(c)

Using SST and a press, install a new output shaft rear ra-
dial ball bearing.
SST

09316–60011 (09316–00011, 09316–00071)

NOTICE:
Install the output shaft rear radial ball bearing so that the
groove for the snap ring does not face the drive sprocket.

2.

INSTALL SYNCHRONIZER RING SET

3.

INSTALL FRONT DRIVE CLUTCH SLEEVE

4.

INSTALL CLUTCH HUB

(a)

Install the 3 shifting keys to the clutch hub.

(b)

Install the 2 shifting key springs to the clutch hub.

NOTICE:
Position the shifting key springs so that their end gaps are
not aligned.

F19279

F19278

F19276

F19277

TR–32

–

TRANSFER

REAR OUTPUT SHAFT

2970

(c)

Install the output shaft plate washer and output shaft front
needle roller bearing to the output shaft rear.

(d)

Install the clutch hub to the output shaft rear.

5.

INSTALL CENTER DIFFERENTIAL CASE

(a)

Install the center differential case to the output shaft rear.

(b)

Install the ball and output shaft spacer No. 2 to the center
differential case.

(c)

Using a snap ring expander, install the snap ring.

6.

INSPECT DRIVE SPROCKET THRUST CLEARANCE

Using a feeler gauge, measure the thrust clearance of the drive
sprocket.

Standard clearance:
0.15 to 0.24 mm (0.0059 to 0.0094 in.)
Maximum clearance:
0.24 mm (0.0094 in.)

If the clearance exceeds the maximum, replace the drive
sprocket.

7.

INSPECT DRIVE SPROCKET RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance of the drive
sprocket.

Standard clearance:
0.01 to 0.06 mm (0.0004 to 0.0024 in.)
Maximum clearance:
0.06 mm (0.0024 in.)

If the clearance exceeds the maximum, replace the drive
sprocket, output shaft rear or needle roller bearing.

TR04O–04

F19233

 Oil Seal Ring

Input Shaft

 Non–reusable part

–

TRANSFER

INPUT SHAFT

TR–33

2971

INPUT SHAFT

COMPONENTS

TR0DK–01

F19268

F19269

F19270

F19298

TR–34

–

TRANSFER

INPUT SHAFT

2972

INSPECTION

1.

REMOVE 2 OIL SEAL RINGS

2.

INSPECT INPUT SHAFT

(a)

Using a micrometer, measure the outer diameter of the in-
put shaft journal surface.
Minimum diameter: 47.59 mm (1.8736 in.)

If the outer diameter is less than the minimum, replace the input
shaft.

(b)

Using a dial indicator, measure the inside diameter of the
input shaft bushing.
Maximum diameter: 48.14 mm (1.8953 in.)

If the inside diameter exceeds the maximum, replace the input
shaft.

3.

INSTALL 2 OIL SEAL RINGS

HINT:

Apply gear oil to the oil seal ring.

Engage securely to eliminate clearance as shown in the
illustration.