Repair Procedure

Front Differential Damper Installation/Replacement
(55 - 65 mph Vibration/Drone Only)





1. Confirm if the vehicle has the original differential dynamic damper installed.





2. Remove the engine under cover front (refer to Figure 2).

3. Remove the engine under cover sub-assembly No.1 (refer to Figure 2).

4. Remove the differential dynamic damper assembly from the front differential support No.1.

5. Install the NEW differential dynamic damper assembly with 2 new bolts (see Figure 1).

Torque: 25 N.m (250 kgf.cm, 18 ft.lbs)

6. Test drive the vehicle and confirm the vibration/drone heard between 55 - 65 mph is eliminated. Repair is complete.

Transfer Case Drive Chain Replacement/Transfer Case Dynamic Damper Installation (70 - 75 mph Vibration/Drone Only)

1. Drain the transfer oil.





2. Remove the transfer case lower protector by removing the 4 bolts.

3. Remove the automatic transmission assembly. Refer to the Technical Information System (TIS):

^ 2003, 2004, or 2005 model year GX 470 Repair Manual: Drivetrain - Automatic Transmission/Transaxle - 'Automatic Transmission Assy: Replacement"

^ 2006 or 2007 model year GX 470 Repair Manual: Drivetrain - Automatic Transmission/Transaxle - 'A750F Automatic Transmission: Automatic Transmission Assembly: Removal"





4. Remove the transfer assembly. Remove the 8 bolts and 2 clamps from the transmission.





5. Remove the actuator motor breather hoses.





6. Remove the switches. Remove the indicator No.1 and No.2 switches, case No.1 plug, and gaskets.





7. Remove the transfer gear shift head No.2.

Using a pin punch and hammer, remove the slotted pin from the gear shift head No.2.





8. Remove the transfer RH bearing retainer sub-assembly by removing the 5 bolts.

If necessary, tap the extension housing with a plastic hammer to remove it.

9. Remove the transfer cover type T oil seal.

Using a screwdriver and hammer, remove the oil seal from the bearing retainer sub-assembly.





10. Remove the transfer case cover sub-assembly by removing the 4 bolts.

11. Remove the breather oil deflector.





12. Remove the front output shaft companion flange sub-assembly.

A. Using a chisel and hammer loosen the staked part of the output shaft companion flange lock nut.

B. Using the SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut.

^ SST P/N 09330-00021





C. Using the SSTs, remove the front output shaft companion flange sub-assembly.

^ SST P/N 09950-40011-02
(09951-04020, 09952-04010,
09953-04030, 09954-04010,
09955-04051, 09957-04010,
09958-04011)

13. Remove the front transfer output shaft companion flange oil seal.

Using a screwdriver and hammer, remove the oil seal from the output shaft companion flange sub-assembly.

14. Remove the rear output shaft companion flange sub-assembly in the same way as the front output shaft companion flange sub-assembly (step 12).

15. Remove the rear transfer output shaft companion flange oil seal.

Using a screwdriver and hammer, remove the oil seal from the rear output shaft companion flange sub-assembly.





16. Remove the extension housing assembly by removing the 5 bolts.

If necessary, tap the extension housing assembly rear with a plastic hammer to remove it.

17. Remove the transfer extension housing type T oil seal. Using a screwdriver and hammer, remove the oil seal.





18. Remove the 2 transfer output washers and collar.





19. Remove the transfer case rear by removing the 12 bolts and 2 clamps.

If necessary, tap the transfer case rear with a plastic hammer to remove it.





20. Remove the transfer gear shift fork No.2 w/transfer high and low clutch sleeve.

A. Using a hexagon wrench, remove the plug No.1.

B. Using a magnetic finger, remove the spring and ball from the hole.

C. Using a pin punch and hammer, drive out the slotted spring pin.

D. Remove the gear shift fork No.2 and high and low shift fork shaft.

E. Remove the high and low clutch sleeve.





21. Remove the center differential lock fork sub-assembly w/front drive clutch sleeve.

A. Using 2 screwdrivers and a hammer, tap out the snap ring.





B. Remove the bolt, center differential lock fork sub-assembly, and front drive clutch sleeve.





22. Remove the rear output shaft sub-assembly, front drive chain, and driven sprocket sub-assembly.

A. Using a snap ring expander, remove the snap ring.

B. Mount the transfer case rear in a vise.





C. Using a plastic hammer, carefully tap the transfer case rear, and remove the rear output shaft sub-assembly together with the front drive chain and the driven sprocket sub-assembly.





D. Remove the rear output shaft sub-assembly, front drive chain, and driven sprocket sub-assembly.

23. Replace the front drive chain with the NEW revised chain assembly.

24. Using a screwdriver and hammer, remove the transfer case oil seal No.1 and No.2.

25. Install the transfer case oil seal.





A. Using the SST (or equivalent tool) and a hammer, drive in a NEW oil seal until its surface is flush with the case upper surface (No.1).

SST P/N 09316-60011 (09316-00011, or equivalent)

B. Coat the lip of the oil seal with MP grease.





C. Using the SST (or equivalent tool) and a hammer, drive in a NEW oil seal until its surface is flush with the case upper surface (No.2).

^ SST P/N 09304-12012
(or equivalent)

Oil seal drive in depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)

D. Coat the lip of the oil seal with MP grease.





26. Install the rear output shaft sub-assembly, front drive chain, and driven sprocket sub-assembly.

A. Install the rear output shaft sub-assembly and driven sprocket to the front drive chain.





B. Install the rear output shaft sub-assembly, front drive chain, and driven sprocket sub-assembly to the case rear.

HINT:
Check that the rear output shaft sub-assembly and driven sprocket sub-assembly turn lightly. If necessary, heat the rear case to about 122 - 176°F (50 - 80°C).





C. Using a snap ring expander, install the snap ring.

27. Install the center differential lock fork sub-assembly w/front drive clutch sleeve.

A. Install the center differential lock fork sub-assembly and front drive clutch sleeve.

B. Install the bolt.

Torque: 24 N.m
(245 kgf.cm, 18 ft.lbf)

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

NOTE:
Make sure to install the fork and clutch sleeve in the correct direction.

28. Install the transfer gear shift fork No.2 w/transfer high and low clutch sleeve.





A. Install the gear shift fork No.2 and high and low shift fork shaft and high and low clutch sleeve.

Make sure to install the fork in the correct direction.

B. Apply sealant to the plug No.1 threads.

^ Sealant: P/N 08833-00080, Toyota Genuine Adhesive 1344, Three Bond 1344, Loctite 242, or equivalent

C. Install the spring and ball to the hole.

D. Install the plug No.1 to the hole.

Torque: 18.6 N.m (190 kgf.cm, 14 ft.lbf)

E. Using a pin punch and hammer, Install the slotted pin.





29. Install the transfer rear case.

A. Apply FIPG sealant to the transfer rear case, as shown.

^ FIPG sealant:
P/N 08826-00090, Three Bond 1281, or equivalent





B. Install the 2 clamps and transfer rear case with the 12 bolts.

Torque: 28 N.m (285 kgf.cm, 21 ft.lbf)





30. Install the collar and 2 transfer output washers.





31. Install the transfer extension housing type T oil seal.

A. Using the SSTs and a hammer, drive in a NEW oil seal until its surface is flush with the housing upper surface.

SST P/N 00002-62091-02 (09223-46011), 09631-32020

B. Coat the lip of the oil seal with MP grease.





32. Install the extension housing assembly.

A. Apply FIPG sealant to the extension housing assembly rear, as shown.

^ FIPG sealant:

P/N 08826-00090, Three Bond 1281, or equivalent

B. Apply sealant to the bolt threads.

^ Sealant: P/N 08833-00080, Toyota Genuine Adhesive 1344, Three Bond 1344, Loctite 242, or equivalent





C. Install the extension housing assembly with the 5 bolts.

Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)





33. Install the front transfer output shaft companion flange oil seal.

A. Using the SSTs and a hammer, drive in a NEW oil seal.

^ SST P/N 09950-60010-02
(09951-00320-01),
09950-70010-02
(09951-07100-01)

B. Coat the lip of the oil seal with MP grease.

34. Install the rear transfer output shaft companion flange oil seal.

A. Using the SSTs and a hammer, drive in a NEW oil seal.

^ SST P/N 09950-60010-02
(09951-00320-01),
09950-70010-02
(09951-07100-01)

B. Coat the lip of the oil seal with MP grease.





35. Install the front output shaft companion flange sub-assembly.

A. Install the companion flange sub-assembly to the drive sprocket sub-assembly.

B. Using the SST to hold the companion flange, install a NEW companion flange lock nut.

SST P/N 09330-00021
Torque: 118 N.m
(1,203 kgf.cm, 87 ft.lbf)

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

36. Install the rear output shaft companion flange sub-assembly.

Using the SST, install the rear companion flange sub-assembly in the same way as the front companion flange sub-assembly.

SST P/N 09330-00021 Torque: 118 N.m
(1,203 kgf.cm, 87 ft.lbf)





37. Install the breather oil deflector.

38. Install the transfer case cover sub-assembly with the 4 bolts.
Torque: 18 N.m
(184 kgf.cm, 13 ft.lbf)





39. Install the transfer cover type T oil seal.

A. Using the SSTs and a hammer, drive in a NEW oil seal until its surface is flush with the retainer upper surface.

^ SST P/N 09950-60010-02
(09951-00590-01),
09950-70010-02
(09951-07100-01)

B. Coat the lip of the oil seal with MP grease.





40. Install the transfer RH bearing retainer sub-assembly.

A. Apply FIPG sealant to the bearing retainer sub-assembly, as shown.

^ FIPG sealant:

P/N 08826-00090, Three Bond 1281, or equivalent

B. Apply sealant to the bolt thread.

^ Sealant: P/N 08833-00080, Toyota Genuine Adhesive 1344, Three Bond 1344, Loctite 242, or equivalent





C. Install the bearing retainer sub-assembly with the 5 bolts.

Torque: 11.5 N.m (117 kgf.cm, 8 ft.lbf)





41. Install the transfer gear shift head No.2.

Using a pin punch and hammer, install the slotted pin to the gear shift head No.2.





42. Install the switches.

Install NEW gaskets, the indicator switches, and the case No.1 plug.

Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)

43. Install hoses.

^ Place the hose between the transfer rear case and the actuator motor.

^ Adjust the clamp position to prevent excessive bending, pulling, or pushing on the hose.

44. Install the transfer assembly.

A. Install the transfer to the automatic transmission.

B. Install the 2 clamps and 8 bolts.

Torque: 24 N.m (245 kgf.cm, 17 ft.lbf)

45. Install the automatic transmission assembly. Refer to TIS:

^ 2003, 2004, or 2005 model year GX 470 Repair Manual: Drivetrain - Automatic Transmission/Transaxle - 'Automatic Transmission Assy: Replacement"

^ 2006 or 2007 model year GX 470 Repair Manual: Drivetrain - Automatic Transmission/Transaxle - 'A 750F Automatic Transmission: Automatic Transmission Assembly: Installation"

46. Install the transfer case lower protector with the 4 bolts.

Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)

47. Add transfer oil.

Refer to TIS:

^ 2003, 2004, or 2005 model year GX 470 Repair Manual: Drivetrain - Transfer/4wd/Awd - "Transfer Oil: Adjustment"

^ 2006 or 2007 model year GX 470 Repair Manual: Drivetrain - Transfer/4wd/Awd

- "VF4BM Transfer: Transfer Oil: Adjustment"





48. Install the dynamic damper to the transfer case with 2 bolts.

Torque: 38 N.m (387 kgf.cm, 28 ft.lbf)





49. Test drive the vehicle to confirm the vibration/drone is eliminated.