Page 3105 of 3115

D02754FIPG5 mm (0.20 in.)
D02863
D02667
Z18975
A
Z18976
B
- TRANSFERTRANSFER ASSEMBLY
TR-15
1903 Author: Date:
2004 LAND CRUISER (RM1071U)
12. INSTALL CASE COVER
(a) Apply FIPG to the rear case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(b) Install the case cover.
(c) Apply liquid sealer to the bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Install the 5 bolts.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
13. INSTALL OIL STRAINER TO REAR CASE
Install the oil strainer and 2 bolts.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
14. SELECT ADJUSTING SHIM FOR IDLER GEAR REAR
TAPER ROLLER BEARING
(a) Using vernier calipers, measure dimension ºAº.
(b) Lightly hole down the bearing outer race in the thrust
direction to eliminate any looseness before making the
measurement.
(c) Using a steel straight edge and feeler gauge, measure
the clearance of dimension ºBº.
(d) Calculate the required thickness of the adjusting shim.
Thickness: Dimension ºAº + Dimension ºBº + [0.022
- 0.049 mm, (0.0009 - 0.0019 in.)]
Page 3106 of 3115

TF1063
C
TF1064
F
E
D
TF1065
F
GH TR-16
- TRANSFERTRANSFER ASSEMBLY
1904 Author: Date:
2004 LAND CRUISER (RM1071U)
(e) From the following table, select a shim so that its thick-
ness is within the range of the calculation.
MarkThickness mm (in.)MarkThickness mm (in.)
20.30 (0.0118)83.20 (0.1260)
30.45 (0.0177)93.40 (0.1339)
42.40 (0.0945)103.60 (0.1417)
52.60 (0.1024)113.80 (0.1496)
62.80 (0.1102)124.00 (0.1575)
73.00 (0.1181)130.55 (0.0216)
15. SELECT ADJUSTING SHIM FOR OUTPUT SHAFT TA-
PER ROLLER BEARING
(a) Using a steel straight edge and feeler gauge, measure
the clearance of dimension ºCº.
(b) Lightly hold down the bearing outer race in the thrust
direction to eliminate any looseness before making the
measurement.
(c) Using a steel straight edge and vernier calipers with depth
gauge, measure dimension ºDº.
(d) Dimension ºDº is the straight edge thickness (Dimension
ºFº) subtracted from dimension ºEº in the illustration to the
left.
Dimension ºDº: Dimension ºEº - Dimension ºFº
(e) Using a steel straight edge and vernier calipers with depth
gauge, measure dimension ºGº.
(f) Dimension ºGº is the straight edge thickness (Dimension
ºFº) subtracted from Dimension ºHº.
Dimension ºGº: Dimension ºHº - Dimension ºFº
(g) Calculate the required thickness of the adjusting shim.
Thickness: Dimension ºGº - (Dimension ºDº - Di-
mension ºCº) + [0.014 ~ 0.039 mm, (0.0006 ~ 0.0015
in.)]
(h) From the following table, select a shim so that its thick-
ness is within the range of the calculation.
MarkThickness mm (in.)MarkThickness mm (in.)
B0.30 (0.0118)H1.80 (0.0709)
C0.45 (0.0177)J2.00 (0.0787)
D1.00 (0.0394)K2.20 (0.0866)
E1.20 (0.0472)L2.40 (0.0945)
F1.40 (0.0551)M2.60 (0.1024)
G1.60 (0.0630)N0.55 (0.0216)
Page 3107 of 3115

D01995
FIPG 3 mm (0.12 in.)
D02861
Q00541
Front
D01991
FIPG
4 mm (0.16 in.)
D02860
- TRANSFERTRANSFER ASSEMBLY
TR-17
1905 Author: Date:
2004 LAND CRUISER (RM1071U)
16. INSTALL REAR EXTENSION HOUSING
(a) Apply FIPG to the rear extension housing.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(b) Install the rear extension housing and 9 bolts.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
17. ASSEMBLE SHIFT FORK NO. 2 SHAFT AND SHIFT
FORK NO. 2
(a) Install the shift fork No. 2 to the shift fork No. 2 shaft.
(b) Install the 3 snap rings to the shift fork No. 2 shaft.
18. INSTALL CLUTCH SLEEVE WITH SHIFT FORK NO. 2
SHAFT AND SHIFT FORK NO. 2
HINT:
Make sure to install the clutch sleeve in the correct direction.
19. INSTALL FRONT EXTENSION HOUSING
(a) Apply FIPG to the front extension housing.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(b) Install the front extension housing and 6 bolts.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
HINT:
Set the clutch sleeve in differential lock condition.
20. INSTALL TRANSFER INDICATOR SWITCH
Install the 3 transfer indicator switches with 3 new gaskets.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
Page 3108 of 3115
Q07105
D02862
D02666FIPG4 mm (0.16 in.)
Q04610
D02690
TR-18
- TRANSFERTRANSFER ASSEMBLY
1906 Author: Date:
2004 LAND CRUISER (RM1071U)
21. INSTALL BALL, SPRING AND SCREW
(a) Install the ball and spring.
(b) Apply liquid sealer to the screw plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(c) Using a torx socket wrench (T40), install the screw plug.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
22. INSTALL OUTPUT GEAR TO FRONT CASE
HINT:
Apply gear oil to the output gear.
NOTICE:
Do not turn the output gear.
23. INSTALL MOTOR ACTUATOR
(a) Apply FIPG to the motor actuator.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
HINT:
Set the motor actuator in differential lock condition.
(b) Install the motor actuator and 4 bolts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
24. INSTALL SPEED SENSOR DRIVE GEAR
Install the driven gear and bolt.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
25. INSTALL BREATHER HOSE
Page 3109 of 3115
TR064-02
- TRANSFERTRANSFER SYSTEM
TR-1
1889 Author: Date:
2004 LAND CRUISER (RM1071U)
TRANSFER SYSTEM
PRECAUTION
When working with FIPG material, you must observe the following.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-
faces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non-residue solvent.
Apply FIPG in an approx. 1.2 mm (0.047 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.
Page 3110 of 3115
TR066-02
D02887
Transfer Indicator Switch
Connector
(Neutral Switch)
Transfer Indicator
Switch Connector
(Center Diff. Lock)Transfer Indicator Switch Connector
(Low Switch)
Motor Actuator Connector
No. 1 Vehicle Speed Sensor Connector Rear Propeller Shaft
Breather Hose
Transfer
Ground Cable
106 (1,080, 78)
69 (700, 51)
69 (700, 51)
Clip
Plate Washer
Wave Washer
Transfer Shift Lever Rod
AssemblyBushing
69 (700, 51)
69 (700, 51)
Transfer Case Protector
: Specified torque
N´m (kgf´cm, ft´lbf)Front Propeller ShaftCrossmember
50 (510, 37)
50 (510, 37)
74 (750, 54)
50 (510, 37)
28 (290, 21)
106 (1,080, 78)
106 (1,080, 78)
106 (1,080, 78)
80 (820, 59)
80 (820, 59)
80 (820, 59)
80 (820, 59)
- TRANSFERTRANSFER UNIT
TR-3
1891 Author: Date:
2004 LAND CRUISER (RM1071U)
TRANSFER UNIT
COMPONENTS
Page 3111 of 3115
TR068-02
TR-6
- TRANSFERTRANSFER UNIT
1894 Author: Date:
2004 LAND CRUISER (RM1071U)
INSTALLATION
Installation is in the reverse order of removal (See page TR-4).
HINT:
Apply MP grease to the transfer adaptor oil seal.
After install, do the road test.
Page 3112 of 3115

TR067-02
D02645
D02646
Oil Level
0 - 5 mm
Filler Plug
Drain Plug
D01618
Q09803
Wooden Block TR-4
- TRANSFERTRANSFER UNIT
1892 Author: Date:
2004 LAND CRUISER (RM1071U)
REMOVAL
1. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
2. REMOVE TRANSFER CASE PROTECTOR
Remove the 3 bolts and transfer case protector.
Torque: 28 N´m (290 kgf´cm, 21 ft´lbf)
3. DRAIN TRANSFER OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75 W-90
Capacity: 1.3 liters (1.4 US qts, 1.1 lmp. qts)
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
4. REMOVE FRONT AND REAR PROPELLER SHAFTS
(See page PR-4)
5. DISCONNECT TRANSFER SHIFT LEVER ROD AS-
SEMBLY
Remove the clip, plate washer, wave washer and bushing, and
disconnect the transfer shift lever rod assembly.
6. DISCONNECT GROUND CABLE
Remove the bolt and disconnect the ground cable from the
transfer.
7. REMOVE CROSSMEMBER
(a) Support the transmission, as shown.
NOTICE:
Use a wooden block so not to damage the transmission oil
pan.
(b) Remove the 8 bolts, 2 nuts and crossmember.
Torque:
Bolt: 50 N´m (510 kgf´cm, 37 ft´lbf)
Nut: 74 N´m (750 kgf´cm, 54 ft´lbf)