Page 3225 of 3371
TF-100
FRONT OIL SEAL
Revision: August 20072004 QX56
INSTALLATION
1. Install the oil seal until it is flush with the end face of the front
case, using Tool.
CAUTION:
Do not reuse oil seal.
Apply petroleum jelly to oil seal.
2. Align the matching mark of the front drive shaft with the match-
ing mark of the companion flange, then install the companion
flange.
3. Install the self-lock nut. Tighten to the specified torque, using
Tool. Refer to TF-110, "
Transfer Components" .
CAUTION:
Do not reuse self-lock nut.
4. Install the front propeller shaft. Refer to PR-4, "
Removal and
Installation" .
5. Refill the transfer with fluid and check fluid level. Refer to MA-
24, "Changing Transfer Fluid" .
6. Check the transfer for fluid leakage. Refer to MA-24, "
Checking
Transfer Fluid" . Tool number : KV38100500 ( — )
SDIA2662E
SDIA2658E
Tool number : KV40104000 ( — )
LDIA0147E
Page 3226 of 3371

REAR OIL SEAL
TF-101
C
E
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MA
B
TF
Revision: August 20072004 QX56
REAR OIL SEALPFP:33140
Removal and InstallationEDS00316
REMOVAL
1. Partially drain the transfer fluid. Refer to MA-24, "Changing Transfer Fluid" .
2. Remove the rear propeller shaft. Refer to PR-8, "
Removal and Installation" .
3. Remove the dust cover from the rear case.
CAUTION:
Do not damage the rear case.
4. Remove the rear oil seal from the rear case, using Tool.
CAUTION:
Do not damage the rear case.
INSTALLATION
1. Install the oil seal until it is flush with the end face of the rear
case, using Tool.
CAUTION:
Do not reuse oil seal.
Apply petroleum jelly to oil seal.
2. Apply petroleum jelly to the circumference of the new dust cover.
Position the dust cover using the identification mark as shown.
CAUTION:
Do not reuse dust cover.
Position the identification mark at the position shown.
WDIA0127E
Tool number : ST33290001 (J-34286)
LDIA0139E
Tool number : ST30720000 (J-25405)
LDIA0140E
SDIA2208E
Page 3227 of 3371
TF-102
REAR OIL SEAL
Revision: August 20072004 QX56
3. Install the dust cover to the rear case, using Tool.
CAUTION:
Do not reuse dust cover.
Apply petroleum jelly to dust cover.
4. Install the rear propeller shaft. Refer to PR-8, "
Removal and
Installation" .
5. Refill the transfer with fluid and check fluid level. Refer to MA-
24, "Changing Transfer Fluid" .
6. Check the transfer for fluid leakage. Refer to MA-24, "
Checking
Transfer Fluid" . Tool number : KV40105310 ( — )
PDIA0 116 E
Page 3228 of 3371
SIDE OIL SEAL
TF-103
C
E
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TF
Revision: August 20072004 QX56
SIDE OIL SEALPFP:33142
Removal and InstallationEDS00317
REMOVAL
1. Remove the front propeller shaft. Refer to PR-4, "Removal and Installation" .
2. Remove the companion flange. Refer to TF-99, "
Removal and Installation" .
3. Remove the transfer control device from the transfer assembly. Refer to TF-104, "
Removal and Installa-
tion" .
4. Remove the side oil seal.
CAUTION:
Do not damage shift cross.
INSTALLATION
1. Install the side oil seal until it is flush with the end face of case,
using Tool.
CAUTION:
Do not reuse oil seal.
Apply petroleum jelly to oil seal.
2. Install the transfer control device to the transfer assembly. Refer
to TF-104, "
Removal and Installation" .
3. Install the companion flange. Refer to TF-99, "
Removal and
Installation" .
4. Install the front propeller shaft. Refer to PR-4, "
Removal and Installation" .
SDIA2666E
Tool number : ST22360002 (J-25679-01)
SDIA2665E
Page 3229 of 3371
TF-104
TRANSFER CONTROL DEVICE
Revision: August 20072004 QX56
TRANSFER CONTROL DEVICEPFP:33251
Removal and InstallationEDS00318
Refer to the figure for transfer control device removal and installation information.
CAUTION:
Change vehicle state to 2WD or AUTO, and then remove and install transfer control device.
Check 4WD shift indicator after installation.
1. Shift lever 2. Actuator
SDIA2654E
Page 3230 of 3371
AIR BREATHER HOSE
TF-105
C
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MA
B
TF
Revision: August 20072004 QX56
AIR BREATHER HOSEPFP:31098
Removal and InstallationEDS00319
Refer to the figure for air breather hose removal and installation information.
CAUTION:
Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
Install the air breather hose into the air breather (metal connector) and actuator (case connector)
until the hose end reaches the base of the tube.
Install the air breather hose into the breather tube (metal connector) and transfer motor (case con-
nector) until the hose end reaches the end of the curved section.
SDIA2656E
Page 3231 of 3371
TF-106
TRANSFER MOTOR
Revision: August 20072004 QX56
TRANSFER MOTORPFP:00000
Removal and InstallationEDS0018R
REMOVAL
1. Disconnect transfer motor harness connector.
2. Remove breather pipe from transfer motor.
3. Remove bolts to detach transfer motor.
NOTE:
After removing transfer motor, be sure to replace O-ring with
new one.
INSTALLATIONEDS0018S
1. Apply ATF or petroleum jelly to new O-ring.
NOTE:
Do not reuse O-ring.
2. Align width across flat-notch with oil pump groove, and install
transfer motor.
3. Tighten bolts.
4. Install breather pipe to transfer motor.
5. Connect transfer motor harness connector.
SDIA2133E
Transfer motor bolts : 45 N·m (4.6 kg-m, 33 ft-lb)
SDIA2185E
Page 3232 of 3371
TRANSFER OIL FILTER
TF-107
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B
TF
Revision: August 20072004 QX56
TRANSFER OIL FILTERPFP:00000
Removal and InstallationEDS0031A
REMOVAL
1. Remove the oil filter bolts and oil filter.
CAUTION:
Do not damage center case and oil filter.
Loosen bolts and detach oil filter evenly.
2. Remove the O-rings (1) from the oil filter (2).
3. Remove the oil filter stud from the oil filter.
4. Remove the O-ring from the oil filter stud.
INSTALLATION
1. Apply ATF to the O-ring, and install it on the oil filter stud.
CAUTION:
Do not reuse O-ring.
2. Install the oil filter stud to the oil filter.
SMT875C
WDIA0285E
SDIA2784E
SDIA2784E