Toyota RAV4 manuals

Toyota Sienna Service Manual: Disassembly

1. REMOVE TRANSFER COVER GASKET

REMOVE TRANSFER COVER GASKET

(a) Remove the transfer gasket from the transfer assembly.

2. REMOVE TRANSFER CASE BREATHER PLUG

REMOVE TRANSFER CASE BREATHER PLUG

(a) Using a screwdriver and a hammer, remove the transfer case breather plug from the No. 1 transfer case cover.

NOTICE: Be careful not to damage the contact surface of No. 1 case cover.

3. REMOVE NO. 1 TRANSFER CASE COVER

REMOVE NO. 1 TRANSFER CASE COVER

(a) Remove the 8 bolts.

 REMOVE NO. 1 TRANSFER CASE COVER

(b) Using a brass bar and a hammer, remove the No. 1 transfer case cover from the transfer case.

NOTICE: Be careful not to damage the contact surfaces of the case and cover.

4. REMOVE BREATHER OIL DEFLECTOR

REMOVE BREATHER OIL DEFLECTOR

(a) Remove the bolt and breather oil deflector from the No. 1 transfer case cover.

5. REMOVE TRANSFER DYNAMIC DAMPER

REMOVE TRANSFER DYNAMIC DAMPER

(a) Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing subassembly.

6. REMOVE TRANSFER CASE STRAIGHT PIN

(a) Remove the 4 transfer case straight pins from the transfer case.

7. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT

(a) Remove the 4 transfer and transaxle setting stud bolts.

8. FIX TRANSFER ASSEMBLY

(a) Fix the transfer assembly to the overhaul attachment.

9. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR

(a) Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.

REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR

10. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

 REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

(a) Using SST(s), remove the transfer extension housing type T oil seal from the transfer extension housing

SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.

11. REMOVE TRANSFER EXTENSION HOUSING SUBASSEMBLY

REMOVE TRANSFER EXTENSION HOUSING SUBASSEMBLY

(a) Remove the 4 bolts.

REMOVE TRANSFER EXTENSION HOUSING SUBASSEMBLY

(b) Using a plastic hammer, remove the transfer extension housing sub- assembly from the transfer case.

12. INSPECT PRELOAD

INSPECT PRELOAD

(a) Using SST(s) and a torque wrench, check the initial torque with the backlash range.

SST 09326-20011 Torque: 0.9 to 1.4 N*m (9 to 14 kgf*cm, 8.0 to 12.4 in.*lbf)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)

(b) Using SST(s) and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.

SST 09326-20011 Torque: Preload + 0.15 to 0.30 N*m (+ 1.6 to 3.1 kgf*cm, + 1.3 to 2.7 in.*lbf)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)

13. REMOVE CTR DIFFERENTIAL LOCK SLEEVE

REMOVE CTR DIFFERENTIAL LOCK SLEEVE

(a) Using snap ring pliers, remove the shaft snap ring.

REMOVE CTR DIFFERENTIAL LOCK SLEEVE

(b) Using SST(s), remove the CTR differential lock sleeve.

SST 09308-00010

14. REMOVE O-RING

(a) Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.

REMOVE O-RING

NOTICE: Be careful not to damage the lock sleeve's groove for the O-ring.

15. REMOVE TRANSFER CASE OIL SEAL

(a) Using SST(s), remove the transfer case oil seal from the case.

REMOVE TRANSFER CASE OIL SEAL

SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the case.

16. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL

REMOVE TRANSFER RH BEARING RETAINER OIL SEAL

(a) Using SST(s), remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.

SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the retainer.

17. REMOVE TRANSFER RH BEARING RETAINER SUBASSEMBLY

REMOVE TRANSFER RH BEARING RETAINER SUBASSEMBLY

(a) Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.

REMOVE TRANSFER RH BEARING RETAINER SUBASSEMBLY

(b) Using SST, make a clearance between the transfer RH bearing retainer sub-assembly and the transfer case.

SST 09950-00020 (c) Remove the SST.

REMOVE TRANSFER RH BEARING RETAINER SUBASSEMBLY

(d) Using SST, remove the transfer RH bearing retainer sub-assembly from the transfer case.

SST 09520-10021

18. REMOVE O-RING

(a) Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assembly.

REMOVE O-RING

NOTICE: Be careful not to damage the retainer's grooves for the O-rings.

19. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

(a) Fix the transfer RH bearing retainer sub-assembly in a vise.

(b) Using SST(s), remove the center differential case tapered roller bearing RH outer race, transfer ring gear mounting case washer No. 2 and right bearing retainer oil seal No. 2 from the transfer RH bearing retainer sub-assembly.

SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer subassembly.

20. REMOVE SIDE GEAR SHAFT HOLDER BEARING

REMOVE SIDE GEAR SHAFT HOLDER BEARING

(a) Using snap ring pliers, remove the side gear shaft holder hole snap ring.

(b) Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assembly.

21. REMOVE TRANSFER RING GEAR MOUNTING CASE

REMOVE TRANSFER RING GEAR MOUNTING CASE

(a) Remove the transfer ring gear mounting case from the transfer case.

22. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

(a) Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.

NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.

 REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

(b) When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.

NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

(c) Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.

NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

(d) When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.

NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.

23. REMOVE RING GEAR

 REMOVE RING GEAR

(a) Put matchmarks on the transfer ring gear mounting case and the ring gear.

(b) Remove the 12 bolts.

 REMOVE RING GEAR

(c) Using a plastic hammer, remove the ring gear by tapping around its periphery.

NOTICE: Do not damage the teeth of the ring gear.

24. REMOVE TRANSFER GEAR NUT

(a) Using SST(s) and a hammer, unstake the transfer gear nut.

SST 09930-00010

REMOVE TRANSFER GEAR NUT

(b) Using SST(s), remove the transfer gear nut.

REMOVE TRANSFER GEAR NUT

REMOVE TRANSFER GEAR NUT

(c) Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer.

NOTICE:

25. REMOVE TRANSFER DRIVEN PINION FRONT BEARING

REMOVE TRANSFER DRIVEN PINION FRONT BEARING

(a) Using SST(s) and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.

SST 09950-00020

26. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

(a) Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 positions to remove it from the transfer case.

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

27. REMOVE TRANSFER OUTPUT WASHER

(a) Remove the ring gear mounting case plate washer from the transfer case.

28. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

(a) Using brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.

29. REMOVE RING GEAR MOUNTING CASE PLATE WASHER

(a) Remove the transfer output washer from the transfer case.

30. REMOVE TRANSFER DRIVEN PINION REAR BEARING

REMOVE TRANSFER DRIVEN PINION REAR BEARING

(a) Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.

Transfer unit
COMPONENTS ...

Inspection
1. INSPECT PRELOAD (a) Using SST(s) and a torque wrench, check the initial torque within the backlash range. SST 09326-20011 Torque: 0.9 to 1.4 N*m (9 to 14 kgf*cm, 8.0 to 12.4 in.*lbf) HINT ...

Other materials:

Terminals of ECU
1. INSTRUMENT PANEL JUNCTION BLOCK (MULTIPLEX NETWORK BODY ECU)  Disconnect the B6, B7 and B9 ECU connectors. Disconnect the 1A, 1C, 1K, 1L and 1P J/B connectors. Check the voltage or resistance according to the value(s) in the table below (wire harness side connector). ...

Front wiper rubber
COMPONENTS REMOVAL 1. REMOVE FRONT WIPER BLADE  Remove the front wiper blade from the front wiper arm LH. NOTICE: Do not fold down the front wiper arm with the front wiper blade being removed from it. 2. REMOVE FRONT WIPER RUBBER  Remove the front wiper rubber from th ...

Registering a Bluetooth® audio player for the first time
To use the Bluetooth® Audio, it is necessary to register an audio player with the system. Once the player has been registered, it is possible to use the Bluetooth® Audio. For details about registering a Bluetooth® device Turn the Bluetooth® connection setting of your audio player on ...

© 2011-2018 Copyright www.tsienna.net