Page 3089 of 3115
TR06U-02
D03520
Center Diff. Lock Switch
Center Diff. Lock Indicater Light
Transfer Indicator Switch
(Center Diff. Lock)
Motor Actuator
Transfer Indicator Switch
(Low Switch)Center Diff. Lock
Control Relay
Transfer Indicator Switch
(Neutral Switch)
TR-48
- TRANSFERMOTOR SHIFT CONTROL SYSTEM
1936 Author: Date:
2004 LAND CRUISER (RM1071U)
MOTOR SHIFT CONTROL SYSTEM
LOCATION
Page 3090 of 3115
TR06P-02
D04346
Ball
Bearing Dust Deflector
Seal RingRear Output Shaft
Screw Plug
Ball
Rear Extension Housing Driven Rotor Speed Sensor Drive Gear
Drive Rotor Oil Pump CoverSpring Valve Seat
4.9 (50, 43 in.´lbf)
29 (300, 22)
Oil Seal
Snap Ring Snap Ring
Oil Pump
Drive ShaftOil Pump Plate
N´m (kgf´cm, ft´lbf)
: Specified torque
Non-reusable part
Precoated part
4.9 (50, 43 in.´lbf)
TR-40
- TRANSFERREAR EXTENSION HOUSING
1928 Author: Date:
2004 LAND CRUISER (RM1071U)
REAR EXTENSION HOUSING
COMPONENTS
Page 3091 of 3115
TR06Q-02
TF1039
Q00530
TF1033
TF1034
Q08384
- TRANSFERREAR EXTENSION HOUSING
TR-41
1929 Author: Date:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. REMOVE OIL PUMP DRIVE SHAFT
2. REMOVE OIL PUMP COVER
(a) Using a torx socket wrench (T30), remove the 3 screws.
(b) Install the 2 suitable bolts to the pump cover.
(c) Remove the pump cover from the rear extension housing.
3. REMOVE DRIVE ROTOR FROM DRIVEN ROTOR
4. REMOVE DRIVEN ROTOR FROM REAR EXTENSION
HOUSING
5. REMOVE SCREW PLUG, SPRING, BALL AND VALVE
SEAT
(a) Using a hexagon wrench, remove the screw plug.
(b) Using a magnetic finger, remove the spring, ball and valve
seat from the rear extension housing.
Page 3092 of 3115

D04353
TF0959
SST
Q08385
Q08481
SST TR-42
- TRANSFERREAR EXTENSION HOUSING
1930 Author: Date:
2004 LAND CRUISER (RM1071U)
6. REMOVE OIL PUMP PLATE
Remove the 3 bolts and oil pump plate.
7. REMOVE SPEED SENSOR DRIVE GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the speed sensor drive gear.
8. REMOVE REAR OUTPUT SHAFT
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a hammer, remove the rear output shaft.
SST 09325-12010
(c) Remove the 2 seal rings from the rear output shaft.
9. REMOVE DUST DEFLECTOR
(a) Using a screwdriver and hammer, remove the rear exten-
sion housing dust deflector.
(b) Using a screwdriver and hammer, remove the rear output
shaft dust deflector.
10. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal from the rear extension
housing.
11. REMOVE BALL BEARING
(a) Using a screwdriver, remove the snap ring.
(b) Using SST and a press, remove the ball bearing from the
rear extension housing.
SST 09316-6001 1 (09316-00011, 09316-00021)
Page 3093 of 3115

TR06R-02
Q02615
Q02616
Q02617
- TRANSFERREAR EXTENSION HOUSING
TR-43
1931 Author: Date:
2004 LAND CRUISER (RM1071U)
INSPECTION
1. INSPECT DRIVEN ROTOR BODY CLEARANCE
(a) Install the drive rotor and driven rotor to the rear extension
housing.
(b) Using a feeler gauge, measure the body clearance be-
tween the drive rotor and extension housing.
Standard clearance:
0.08 - 0.17 mm (0.0031 - 0.0067 in.)
Maximum clearance:
0.17 mm (0.0067 in.)
If the body clearance exceeds the maximum, replace the drive
rotor and driven rotor.
2. INSPECT DRIVEN ROTOR TIP CLEARANCE
Using a feeler gauge, measure the tip clearance between the
drive rotor and driven rotor.
Standard clearance:
0.05 - 0.15 mm (0.0020 - 0.0059 in.)
Maximum clearance:
0.15 mm (0.0059 in.)
If the tip clearance exceeds the maximum, replace the drive ro-
tor and driven rotor.
3. INSPECT OIL PUMP SIDE CLEARANCE
Using a steel straight edge and feeler gauge, measure the side
clearance of oil pump.
Standard clearance:
0.03 - 0.10 mm (0.0012 - 0.0039 in.)
Maximum clearance:
0.10 mm (0.0039 in.)
If the side clearance exceeds the maximum, replace the drive
rotor and driven rotor.
Page 3094 of 3115
TR06S-02
TF0964
SST
TF0962
Q08482
SST
TF0967
SST
Q08482
SST TR-44
- TRANSFERREAR EXTENSION HOUSING
1932 Author: Date:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL BALL BEARING
(a) Using SST and a press, install the ball bearing.
SST 09316-6001 1 (09316-00011, 09316-00031)
(b) Select a snap ring that will allow the minimum axial play.
MarkThickness mm (in.)
A1.70 (0.0669)
B1.80 (0.0709)
(c) Using a screwdriver, install a new snap ring.
2. INSTALL DUST DEFLECTOR
(a) Using SST and a hammer, install a new rear extension
housing dust deflector.
SST 09316-6001 1 (09316-00011, 09316-00041)
(b) Using SST and a press, install a new rear output shaft
dust deflector.
SST 09316-2001 1, 09316-60011 (09316-00011)
3. INSTALL OIL SEAL
(a) Apply MP grease to the lip of a new oil seal.
(b) Using SST and a hammer, drive in the oil seal.
SST 09316-6001 1 (09316-00011, 09316-00031)
Page 3095 of 3115
TF0969
SST
TF0958
D04353
- TRANSFERREAR EXTENSION HOUSING
TR-45
1933 Author: Date:
2004 LAND CRUISER (RM1071U)
4. INSTALL REAR OUTPUT SHAFT
(a) Using SST and a press, install the rear output shaft.
SST 09316- 20011, 09316- 60011 (09316- 00011,
09316-00031)
(b) Install the 2 seal rings to the rear output shaft.
(c) Select a snap ring that will allow the minimum axial play.
MarkThickness mm (in.)
11.95 (0.0768)
22.05 (0.0807)
32.15 (0.0847)
42.25 (0.0886)
(d) Using a snap ring expander, install a new snap ring.
5. INSTALL SPEED SENSOR DRIVE GEAR
(a) Install the speed sensor drive gear.
(b) Using a snap ring expander, install the snap ring.
6. INSTALL OIL PUMP PLATE
(a) Install the oil pump plate.
(b) Install and torque the 3 bolts.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
Page 3096 of 3115
Q08384
TF0977
Q00529
TR-46
- TRANSFERREAR EXTENSION HOUSING
1934 Author: Date:
2004 LAND CRUISER (RM1071U)
7. INSTALL VALVE SEAT, BALL, SPRING AND SCREW
PLUG
(a) Apply gear oil to the ball.
(b) Install the valve seat, ball and spring.
(c) Apply liquid sealer to the screw plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Using a hexagon wrench, install and torque the screw
plug.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
8. INSTALL DRIVEN ROTOR
(a) Apply gear oil to the driven rotor.
(b) Install the driven rotor.
9. INSTALL DRIVE ROTOR
(a) Apply gear oil to the drive rotor.
(b) Install the drive rotor.
HINT:
Align the alignment marks.
10. INSTALL OIL PUMP COVER
(a) Install the oil pump cover.
(b) Using a torx socket wrench (T30), install and torque the
3 screws.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
NOTICE:
Align the oil hole of the rear extension housing and oil
groove end of the oil pump cover.
11. INSTALL OIL PUMP DRIVE SHAFT