Page 2977 of 4323
TR0DJ±01
F19283
F19751
SST
Groove
F19281
F19293
F19294
± TRANSFERREAR OUTPUT SHAFT
TR±31
2969 Author: Date:
2005 SEQUOIA (RM1146U)
REASSEMBLY
1. INSTALL DRIVE SPROCKET
(a) Install the output shaft plate washer and drive sprocket
bearing to the output shaft rear.
(b) Install the drive sprocket and output shaft spacer No. 1 to
the output shaft rear.
(c) Using SST and a press, install a new output shaft rear ra-
dial ball bearing.
SST 09316±60011 (09316±00011, 09316±00071)
NOTICE:
Install the output shaft rear radial ball bearing so that the
groove for the snap ring does not face the drive sprocket.
2. INSTALL SYNCHRONIZER RING SET
3. INSTALL FRONT DRIVE CLUTCH SLEEVE
4. INSTALL CLUTCH HUB
(a) Install the 3 shifting keys to the clutch hub.
(b) Install the 2 shifting key springs to the clutch hub.
NOTICE:
Position the shifting key springs so that their end gaps are
not aligned.
Page 2978 of 4323

F19279
F19278
F19276
F19277
TR±32
± TRANSFERREAR OUTPUT SHAFT
2970 Author: Date:
2005 SEQUOIA (RM1146U)
(c) Install the output shaft plate washer and output shaft front
needle roller bearing to the output shaft rear.
(d) Install the clutch hub to the output shaft rear.
5. INSTALL CENTER DIFFERENTIAL CASE
(a) Install the center differential case to the output shaft rear.
(b) Install the ball and output shaft spacer No. 2 to the center
differential case.
(c) Using a snap ring expander, install the snap ring.
6. 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.
7. 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.
Page 2979 of 4323
TR04O±04
F19233
Oil Seal Ring
Input Shaft
Non±reusable part
± TRANSFERINPUT SHAFT
TR±33
2971 Author: Date:
2005 SEQUOIA (RM1146U)
INPUT SHAFT
COMPONENTS
Page 2980 of 4323
TR0DK±01
F19268
F19269
F19270
F19298
TR±34
± TRANSFERINPUT SHAFT
2972 Author: Date:
2005 SEQUOIA (RM1146U)
INSPECTION
1. REMOVE 2 OIL SEAL RINGS
2. INSPECT INPUT SHAFT
(a) Using a micrometer, measure the outer diameter of the in-
put shaft journal surface.
Minimum diameter: 47.59 mm (1.8736 in.)
If the outer diameter is less than the minimum, replace the input
shaft.
(b) Using a dial indicator, measure the inside diameter of the
input shaft bushing.
Maximum diameter: 48.14 mm (1.8953 in.)
If the inside diameter exceeds the maximum, replace the input
shaft.
3. INSTALL 2 OIL SEAL RINGS
HINT:
Apply gear oil to the oil seal ring.
Engage securely to eliminate clearance as shown in the
illustration.
Page 2981 of 4323
TR00N±08
F19235
Input Shaft Bearing
Non±reusable part Low Planetary Gear Bearing
Snap RingLow Planetary GearSnap Ring
Low Planetary Gear
Spline Piece
± TRANSFERPLANETARY GEAR
TR±35
2973 Author: Date:
2005 SEQUOIA (RM1146U)
PLANETARY GEAR
COMPONENTS
Page 2982 of 4323

TR0DL±01
F19271
F19272
F19273
SST
F19295
SST
SST
TR±36
± TRANSFERPLANETARY GEAR
2974 Author: Date:
2005 SEQUOIA (RM1146U)
INSPECTION
1. INSPECT PLANETARY PINION GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the thrust clearance of the plan-
etary pinion gear.
Standard clearance:
0.11 to 0.84 mm (0.0043 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the planetary
gear.
2. INSPECT PLANETARY PINION GEAR RADIAL
CLEARANCE
Using a dial indicator, measure the radial clearance of the plan-
etary pinion gear.
Standard clearance:
0.009 to 0.038 mm (0.0004 to 0.0015 in.)
Maximum clearance:
0.038 mm (0.0015 in.)
If the clearance exceeds the maximum, replace the planetary
gear.
3. IF NECESSARY, REPLACE INPUT SHAFT BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the input shaft bearing.
SST 09554±30011, 09555±55010
(c) Using SST and a press, install a new bearing so that the
groove does not face the low planetary gear.
SST 09223±15020, 09515±30010, 09950±70010
(09951±07100)
Page 2983 of 4323

F19297
F19275
SST
F19296
SST
F19274
± TRANSFERPLANETARY GEAR
TR±37
2975 Author: Date:
2005 SEQUOIA (RM1146U)
(d) Select a snap ring that allows for the minimum axial play.
MarkThickness mm (in.)
11.45 to 1.50 (0.0571 to 0.0591)
21.50 to 1.55 (0.0591 to 0.0610)
31.55 to 1.60 (0.0610 to 0.0630)
41.60 to 1.65 (0.0630 to 0.0650)
51.65 to 1.70 (0.0650 to 0.0669)
(e) Using a snap ring expander, install a new snap ring.
4. IF NECESSARY, REPLACE LOW PLANETARY GEAR
BEARING
(a) Using SST, remove the low planetary gear bearing.
NOTICE:
Engage the claws of the SST securely so that there is no
clearance between the bearing and low planetary gear.
SST 09612±65014 (09612±01030, 09612±01050)
(b) Using SST and a press, drive in a new bearing.
SST 09950±60010 (09951±00570), 09950±70010
(09951±07100)
Bearing press in depth:
7.7 to 8.3 mm (0.303 to 0.327 in.)
5. REMOVE LOW PLANETARY GEAR SPLINE PIECE
(a) Using a screwdriver, remove the snap ring.
(b) Remove the low planetary gear spline piece to the low
planetary gear.
6. INSTALL LOW PLANETARY GEAR SPLINE PIECE
(a) Install the low planetary gear spline piece to the low plan-
etary gear.
(b) Using a screwdriver, install the snap ring.
Page 2984 of 4323
TR0CL±02
F19803
Differential Lock Switch
Transfer Actuator Four Wheel Drive Control ECU
2WD/4HI Switch4LO Switch
TR±38
± TRANSFERONE TOUCH 2±4 SELECTOR SYSTEM
2976 Author: Date:
2005 SEQUOIA (RM1146U)
ONE TOUCH 2±4 SELECTOR SYSTEM
LOCATION