Page 2943 of 4323
D05186
D13880
SST
F07266
D14215
A750E:
A750F:
± AUTOMATIC TRANSMISSION (A750E, A750F)AUTOMATIC TRANSMISSION UNIT
AT±27
2935 Author: Date:
2005 SEQUOIA (RM1146U)
13. DISCONNECT OIL COOLER PIPE
(a) Remove the 3 bolts and clamps.
Torque: 12 N´m (122 kgf´cm, 9 ft´lbf)
(b) Disconnect the 2 oil cooler pipes.
SST 09023±12701
Torque: 34 N´m (346 kgf´cm, 25 ft´lbf)
14. DISCONNECT STABILIZER BAR
(a) Remove the 2 bolts, nuts and stabilizer bar with the bush-
ings and brackets.
Torque: 37 N´m (377 kgf´cm, 27 ft´lbf)
(b) Disconnect the stabilizer bar.
15. REMOVE REAR END PLATE AND TORQUE CON-
VERTER CLUTCH MOUNTING BOLT
(a) Remove the bolt and rear end plate.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
(b) Turn the crankshaft to gain access and remove the 6 bolts
while holding the crankshaft pulley set bolt with a wrench.
Torque: 48 N´m (490 kgf´cm, 35 ft´lbf)
HINT:
At the time of installation, refer to the following:
First install the green colored bolt and then the remaining 5
bolts.
16. JACK UP TRANSMISSION SLIGHTLY
Securely support the transmission on a transmission jack.
Lift the transmission slightly from the crossmember.
Page 2948 of 4323
TR04H±04
TR±2
± TRANSFERTROUBLESHOOTING
2940 Author: Date:
2005 SEQUOIA (RM1146U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help find the cause of the problem. The numbers indicate the priority of the likely cause
of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspected AreaSee page
Noise
1. Oil (Level low)
2. Oil (Wrong)
3. Transfer faultyTR±5
TR±5
TR±7
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O±ring (Worn or damaged)TR±5
TR±7
TR±16
TR±7
Tight corner brakingCenter differential or transfer faultyTR±7
Shift from 2WD (H) to 4WD (H) impossible
1. 4WD fuse
2. Wire harness
3. Vehicle speed sensor
4. 2WD/4HI switch
5. 4WD indicator light
6. Actuator assembly
7. A.D.D. control system
8. 4WD control ECU
9. Transfer assembly±
±
BE±55
TR±39
TR±39
TR±39
SA±61
TR±39
TR±3
Shift from 2WD (H) to 4WD (L4) impossible
1. 4LO switch
2. Wire harness
3. 4WD control ECUTR±39
±
TR±39
Shift from 4WD (H) to 4WD (L4) impossible
1. 4LO switch
2. Wire harness
3. 4WD control ECUTR±9
±
TR±39
Shift from 4WD (H) to 2WD (H) impossible
1. 4WD fuse
2. Wire harness
3. 4WD indicator light
4. Actuator assembly
5. A.D.D. control system
6. 4WD control ECU
7. Transfer assembly±
±
TR±39
TR±39
SA±61
TR±39
TR±3
Shift from 4WD (L4) to 2WD (H) impossible
1. 2WD/4HI switch
2. Wire harness
3. 4WD control ECUTR±39
±
TR±39
Shift from 4WD (L4) to 4WD (H) impossible
1. 2WD/4HI switch
2. Wire harness
3. 4WD control ECUTR±39
±
TR±39
Page 2950 of 4323
TR0DD±01
F19315
F19237
TR±4
± TRANSFERTRANSFER UNIT
2942 Author: Date:
2005 SEQUOIA (RM1146U)
REMOVAL
1. SWITCH TRANSFER TO 2WD
2. REMOVE PROTECTOR
Remove the 4 bolts and protector.
3. DRAIN TRANSFER OIL
4. REMOVE FRONT SUSPENSION MEMBER BRACKET
Remove the 8 bolts and 2 front suspension member brackets.
5. REMOVE LH AND RH FRONT EXHAUST PIPES
(See page EM±126)
6. REMOVE FRONT AND REAR PROPELLER SHAFT
(See page PR±7)
7. REMOVE CROSS MEMBER
(a) Remove the 2 bolts and heat insulator.
(b) Support the rear side of the transmission with a transmis-
sion jack.
(c) Remove the 4 set bolts of the engine rear mounting.
(d) Remove the 4 bolts, nuts and cross member.
8. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the transfer.
9. DISCONNECT VEHICLE SPEED SENSOR AND
TRANSFER ACTUATOR CONNECTORS
10. REMOVE TRANSFER
(a) Support the transfer with another transmission jack.
(b) Remove the 8 transfer mounting bolts.
(c) Pull the transfer out from the transmission down and to-
ward the rear.
Page 2951 of 4323
TR0DE±01
F19237
F19338
0 to 5 mm
(0 to 0.1968 in.)
± TRANSFERTRANSFER UNIT
TR±5
2943 Author: Date:
2005 SEQUOIA (RM1146U)
INSTALLATION
1. INSTALL TRANSFER
Raise the transfer and install it to the transmission with the 8
transfer mounting bolts.
Torque: 24 N´m (245 kgf´cm, 18 ft´lbf)
NOTICE:
Take care not to damage the lip of the transfer rear oil seal
with the transfer input shaft.
2. CONNECT VEHICLE SPEED SENSOR AND TRANS-
FER ACTUATOR CONNECTORS
3. INSTALL ENGINE REAR MOUNTING
Install the engine rear mounting to the transfer with the 4 bolts.
Torque: 65 N´m (660 kgf´cm, 48 ft´lbf)
4. INSTALL CROSS MEMBER
(a) Install the cross member with the 4 bolts and nuts.
Torque: 72 N´m (730 kgf´cm, 53 ft´lbf)
(b) Install the 4 set bolts of the engine rear mounting.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
(c) Remove the transmission jacks.
(d) Install the heat insulator with the 2 bolts.
Torque: 16 N´m (164 kgf´cm, 12 ft´lbf)
5. INSTALL FRONT AND REAR PROPELLER SHAFTS
(See page PR±9)
6. INSTALL LH AND RH FRONT EXHAUST PIPES
(See page EM±128)
7. INSTALL FRONT SUSPENSION MEMBER BRACKET
Install the 2 front suspension member brackets with the 8 bolts.
Torque: 33 N´m (336 kgf´cm, 24 ft´lbf)
8. FILL WITH TRANSFER OIL
(a) Remove the filler plug and gasket.
(b) Fill with transfer oil.
Oil grade: API GL±4 or GL±5
Viscosity: SAE 75W±90
Capacity: 1.4 liters (1.5 US qts, 1.2 lmp.qts)
NOTICE:
When supplying oil, pour it slowly.
Supply oil several times at several minute intervals.
HINT:
The oil level must be within 0 to 5 mm (0 to 0.1968 in.) down from
the lowest end of the hole for the filler plug.
(c) After leaving it for 5 minutes, check the oil level again.
(d) Install the filler plug with a new gasket.
Torque: 37 N´m (377 kgf´cm, 27 ft´lbf)
Page 2953 of 4323
TR0CI±02
F19231
Low Planetary Ring Gear
x5Transfer
Case Cover
Output Shaft Front
Needle Roller Bearing
Oil Pump Gear
Magnet
118 (1,203, 87)
Thrust Bearing Race No. 1
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
Precoated partSnap Ring Case Plug
Breather Oil
Deflector
Front Output Shaft
Companion Flange
Compression Spring
Front Bearing
Retainer
Low Planetary Gear Bearing Low Planetary Gear
Input Gear Stopper
Planetary Carrier Washer
Oil Separator
7.5 (76, 66 in.´lbf)
Oil PumpSnap Ring
Transfer Front
Case
Oil SealSpacer
Snap RingInput Shaft
Ball
Head Pin
O±Ring
Oil Seal Oil Seal
18.6 (190, 14)
18 (184, 13)
11.5 (117, 8)
7.5 (76, 66 in.´lbf)
7.5 (76, 66 in.´lbf)
± TRANSFERTRANSFER ASSEMBLY
TR±7
2945 Author: Date:
2005 SEQUOIA (RM1146U)
TRANSFER ASSEMBLY
COMPONENTS
Page 2954 of 4323
F19232
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
Precoated partTransfer Extension Housing Collar Snap Ring
Transfer Output WasherRear Output Shaft
Companion Flange
24 (245, 18)
Driven Sprocket Front Drive Chain
19 (194, 14)
Shift Shaft Stopper Rear Output Shaft
Sub±assy
Gasket
37 (377, 27)
(Filler Plug) Clamp
28 (286, 21)
x12
Gear Shift Fork No. 1
Rear No. 2 Stopper
Shift ShaftSnap RingTransfer Shift
Actuator
Gasket
Oil Seal High and Low
Clutch Sleeve
Gear Shift Fork No. 2
x5 Front No. 2 Stopper Shift ShaftShift Inter±lock PinFront Drive Shift Fork ShaftTransfer Case Rear Snap Ring20 (204, 15)
No. 1 Plug
37 (377, 27)
(Drain Plug) No. 1 Plug
Oil Seal
12 (122, 9)
20 (204, 15)
118 (1,203, 87)
TR±8
± TRANSFERTRANSFER ASSEMBLY
2946 Author: Date:
2005 SEQUOIA (RM1146U)
Page 2955 of 4323
TR0DF±01
F19238
F19239
F19240
SST
F19241
SST
± TRANSFERTRANSFER ASSEMBLY
TR±9
2947 Author: Date:
2005 SEQUOIA (RM1146U)
DISASSEMBLY
1. REMOVE FRONT BEARING RETAINER
(a) Remove the 5 bolts and front bearing retainer.
HINT:
If necessary, tap on the front bearing retainer with a plastic ham-
mer to remove it.
(b) Using a screwdriver and hammer, remove the oil seal
from the front bearing retainer.
2. REMOVE TRANSFER CASE COVER
Remove the 4 bolts and transfer case cover.
3. REMOVE BREATHER OIL DEFLECTOR
4. REMOVE FRONT OUTPUT SHAFT COMPANION
FLANGE
(a) Using a chisel and hammer, loosen the staked part of the
front output shaft companion flange lock nut.
(b) Using SST to hold the front output shaft companion
flange, remove the output shaft companion flange lock
nut.
SST 09330±00021
(c) Using SST, remove the front output shaft companion
flange.
SST 09950±40011 (09951±04020, 09952±04010,
09953±04030, 09954±04010, 09955±04051,
09957±04010, 09958±04011)
(d) Using a screwdriver and hammer, remove the oil seal
from the front output shaft companion flange.
5. REMOVE REAR OUTPUT SHAFT COMPANION
FLANGE
Remove the rear output shaft companion flange in the same
way as the front output shaft companion flange.
Page 2956 of 4323
F19242
F19243
F19244
F19245
F19246
TR±10
± TRANSFERTRANSFER ASSEMBLY
2948 Author: Date:
2005 SEQUOIA (RM1146U)
6. REMOVE TRANSFER EXTENSION HOUSING
(a) Remove the 5 bolts and transfer extension housing.
HINT:
If necessary, tap on the transfer extension housing with a plas-
tic hammer to remove it.
(b) Using a screwdriver and hammer, remove the oil seal
from the transfer extension housing.
(c) Remove the 2 transfer output washers.
(d) Remove the collar.
7. REMOVE TRANSFER CASE REAR
(a) Remove the 12 bolts and clamp.
(b) Remove the transfer case rear.
HINT:
If necessary, tap on the transfer case rear with a plastic hammer
to remove it.
8. REMOVE GEAR SHIFT FORK NO. 2 AND HIGH AND
LOW CLUTCH SLEEVE
Remove the bolt, gear shift fork No.2 and high and low clutch
sleeve.
9. REMOVE SHIFT SHAFT STOPPER
Remove the bolt and shift shaft stopper.
10. REMOVE FRONT DRIVE SHIFT FORK SHAFT
(a) Turn the front drive shift fork shaft.
(b) Remove the front drive shift fork shaft from the rear case
aligning the cutout with the shift inter±lock pin.
