Page 2969 of 4323
F19239
F19313
SST
F19314
FIPG
F19238
± TRANSFERTRANSFER ASSEMBLY
TR±23
2961 Author: Date:
2005 SEQUOIA (RM1146U)
20. INSTALL BREATHER OIL DEFLECTOR
21. INSTALL TRANSFER CASE COVER
Install the transfer case cover with the 4 bolts.
Torque: 18 N´m (184 kgf´cm, 13 ft´lbf)
22. INSTALL FRONT BEARING RETAINER
(a) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the retainer upper surface.
SST 09950±60010 (09951±00590), 09950±70010
(09951±07100)
(b) Coat the lip of the oil seal with MP grease.
(c) Apply FIPG to the front bearing retainer, as shown.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or
equivalent
(d) Apply sealant to the bolt threads.
FIPG:
Part No. 08826±00080, THREE BOND 1334, LOCTITE
242 or equivalent
(e) Install the front bearing retainer with the 5 bolts.
Torque: 11.5 N´m (117 kgf´cm, 8 ft´lbf)
Page 2970 of 4323
TR00F±08
F19234
Front Bearing
Non±reusable partDriven Sprocket Rear Bearing
TR±24
± TRANSFERDRIVEN SPROCKET
2962 Author: Date:
2005 SEQUOIA (RM1146U)
DRIVEN SPROCKET
COMPONENTS
Page 2971 of 4323
TR00G±08
F19254
F19255
Steel Bar
SST
F19302
SST
F19303
± TRANSFERDRIVEN SPROCKET
TR±25
2963 Author: Date:
2005 SEQUOIA (RM1146U)
REPLACEMENT
1. REMOVE FRONT BEARING
Using a press, remove the front bearing.
2. REMOVE REAR BEARING
Using SST, a press and steel bar, remove the rear bearing.
SST 09555±55010
3. INSTALL REAR BEARING
Using SST and a press, install a new rear bearing.
SST 09316±60011 (09316±00031)
4. INSTALL FRONT BEARING
Using a press, install a new front bearing.
Page 2972 of 4323
TR083±03
F19236
Output Shaft Rear
Radial Ball Bearing Output Shaft Spacer No. 1
Output Shaft Front
Needle Roller Bearing
Synchronizer Ring Set
Front Drive Clutch Sleeve
Non±reusable partCenter Differential Case
Ball
Snap Ring
Output Shaft Spacer No. 2Drive Sprocket
Drive Sprocket Bear-
ing
Output Shaft
Plate Washer
Output Shaft Rear Output Shaft
Plate Washer
Synchromesh Shifting Key Spring
Synchromesh Shifting Key
Clutch Hub
TR±26
± TRANSFERREAR OUTPUT SHAFT
2964 Author: Date:
2005 SEQUOIA (RM1146U)
REAR OUTPUT SHAFT
COMPONENTS
Page 2973 of 4323

TR0DH±01
F19276
F19277
F19278
F19279
± TRANSFERREAR OUTPUT SHAFT
TR±27
2965 Author: Date:
2005 SEQUOIA (RM1146U)
DISASSEMBLY
1. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of the drive
sprocket.
Standard clearance:
0.15 to 0.24 mm (0.0059 to 0.0094 in.)
Maximum clearance:
0.24 mm (0.0094 in.)
If the clearance exceeds the maximum, replace the drive
sprocket.
2. INSPECT DRIVE SPROCKET RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of the drive
sprocket.
Standard clearance:
0.01 to 0.06 mm (0.0004 to 0.0024 in.)
Maximum clearance:
0.06 mm (0.0024 in.)
If the clearance exceeds the maximum, replace the drive
sprocket, output shaft rear or needle roller bearing.
3. REMOVE CENTER DIFFERENTIAL CASE
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the output shaft spacer No. 2 and ball.
(c) Remove the center differential case.
4. REMOVE CLUTCH HUB
Remove the clutch hub, output shaft front needle roller bearing
and output shaft plate washer.
Page 2974 of 4323
F19280
F19281
F19282
SST
F19283
TR±28
± TRANSFERREAR OUTPUT SHAFT
2966 Author: Date:
2005 SEQUOIA (RM1146U)
5. REMOVE FRONT DRIVE CLUTCH SLEEVE
(a) Using a screwdriver, remove the 2 shifting key springs.
(b) Remove the 3 shifting keys.
(c) Remove the front drive clutch sleeve.
6. REMOVE SYNCHRONIZER RING SET
7. REMOVE DRIVE SPROCKET
(a) Using SST and a press, remove the output shaft rear ra-
dial ball bearing.
SST 09555±55010
(b) Remove the output shaft spacer No. 1 and drive sprocket.
(c) Remove the output shaft plate washer and drive sprocket
bearing.
Page 2975 of 4323

TR0DI±01
F19284
A B C D
F19286
± TRANSFERREAR OUTPUT SHAFT
TR±29
2967 Author: Date:
2005 SEQUOIA (RM1146U)
INSPECTION
1. INSPECT OUTPUT SHAFT REAR
Using a micrometer, measure the outer diameter of the output
shaft rear journal surface.
Standard diameter:
Part A: 27.98 to 27.99 mm (1.1016 to 1.1020 in.)
Part B: 31.98 to 32.00 mm (1.2591 to 1.2598 in.)
Part C: 34.98 to 35.00 mm (1.3772 to 1.3780 in.)
Part D: 36.98 to 37.00 mm (1.4559 to 1.4567 in.)
Minimum diameter:
Part A: 27.98 mm (1.1016 in.)
Part B: 31.98 mm (1.2591 in.)
Part C: 34.98 mm (1.3772 in.)
Part D: 36.98 mm (1.4559 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft rear.
2. INSPECT FRONT DRIVE CLUTCH SLEEVE AND
GEAR SHIFT FORK NO. 1 CLEARANCE
(a) Using vernier calipers, measure the thickness of the gear
shift fork No. 1 claw.
Thickness: 10 mm (0.3937 in.)
(b) Using vernier calipers, measure the width of the groove
of the front drive clutch sleeve.
Width: 10.5 mm (0.4134 in.)
(c) Calculate the clearance between the front drive clutch
sleeve and gear shift fork No. 1.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the front drive
clutch sleeve or gear shift fork No. 1.
Page 2976 of 4323

F19285
F19288
F19287
TR±30
± TRANSFERREAR OUTPUT SHAFT
2968 Author: Date:
2005 SEQUOIA (RM1146U)
3. INSPECT HIGH AND LOW CLUTCH SLEEVE AND
GEAR SHIFT FORK NO. 2 CLEARANCE
(a) Using vernier calipers, measure the thickness of the gear
shift fork No. 2 claw.
Thickness: 10 mm (0.3937 in.)
(b) Using vernier calipers, measure the width of the groove
of the high and low clutch sleeve.
Width: 10.5 mm (0.4134 in.)
(c) Calculate the clearance between the high and low clutch
sleeve and gear shift fork No. 1.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the high and
low clutch sleeve or gear shift fork No. 2.
4. INSPECT CENTER DIFFERENTIAL CASE AND FRONT
DRIVE CLUTCH SLEEVE
(a) Check that the tip of the spline gear of the front drive
clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center differen-
tial case and check that the front drive clutch sleeve
moves smoothly.
5. INSPECT CENTER DIFFERENTIAL CASE AND HIGH
AND LOW CLUTCH SLEEVE
(a) Check that the tip of the spline gear of the front drive
clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center differen-
tial case and check that the front drive clutch sleeve
moves smoothly.