Toyota Tundra Service Manual: Inspection

INSPECTION

PROCEDURE

1. INSPECT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (FRONT)

(a) Using a micrometer, measure the outer diameter of the output shaft companion flange sub-assembly (front) journal surface.

Minimum Diameter:

Journal

Specified Condition

A

34.962 mm (1.376 in.)

B

39.955 mm (1.573 in.)

If the outer diameter is less than the minimum, replace the output shaft companion flange sub-assembly (front).

2. INSPECT TRANSFER LOW PLANETARY GEAR ASSEMBLY

(a) Using a feeler gauge, measure the thrust clearance of the pinion gear.

Maximum clearance:

0.93 mm (0.037 in.)

If the clearance is more than the maximum, replace the transfer low planetary gear assembly.

(b) Using a dial indicator, measure the radial clearance of the pinion gear.

Maximum clearance:

0.021 mm (0.0008 in.)

If the clearance is more than the maximum, replace the transfer low planetary gear assembly.

3. INSPECT REAR TRANSFER OUTPUT SHAFT

(a) Using a micrometer, measure the diameter of the rear transfer output shaft journal.

Minimum Diameter:

Journal

Specified Condition

A

29.987 mm (1.181 in.)

B

34.848 mm (1.372 in.)

C

58.000 mm (2.284 in.)

D

49.110 mm (1.934 in.)

E

44.874 mm (1.767 in.)

If the diameter is less than the minimum, replace the rear transfer output shaft.

4. INSPECT SOLENOID LOCK PLATE AND NO. 2 TRANSFER GEAR SHIFT FORK CLEARANCE

(a) Using a vernier caliper, measure the thickness of the No. 2 transfer gear shift fork claw.

Standard thickness (A):

6.90 to 7.06 mm (0.272 to 0.277 in.)

(b) Using a vernier caliper, measure the width of the groove of the solenoid lock plate.

Standard width (B):

7.16 to 7.32 mm (0.282 to 0.288 in.)

(c) Calculate the clearance between the solenoid lock plate and No. 2 transfer gear shift fork claw.

Maximum clearance (B) - (A):

0.42 mm (0.017 in.)

If the clearance is more than the maximum, replace the solenoid lock plate or No. 2 transfer gear shift fork.

5. INSPECT NO. 1 TRANSFER GEAR SHIFT FORK AND NO. 2 TRANSFER GEAR SHIFT FORK

(a) Check the gear shift fork pad for wear or damage.

If necessary, replace the gear shift fork pad.

(b) Using a micrometer, measure the outer diameter of the No. 1 transfer gear shift fork and No. 2 transfer gear shift fork.

Minimum Diameter:

Diameter

Specified Condition

A

12.586 mm (0.496 in.)

B

12.586 mm (0.496 in.)

Text in Illustration

*1

No. 1 Transfer Gear Shift Fork

*2

No. 2 Transfer Gear Shift Fork

If the diameter is less than the minimum, replace the No. 1 transfer gear shift fork or No. 2 transfer gear shift fork.

6. INSPECT TRANSFER HIGH AND LOW CLUTCH SLEEVE

(a) Using a vernier caliper, measure the thickness of the transfer high and low clutch sleeve.

Minimum thickness:

3.00 mm (0.1182 in.)

If the thickness is less than the minimum, replace the transfer high and low clutch sleeve.

7. INSPECT TRANSFER OUTPUT SHAFT SPACER

(a) Using a vernier caliper, measure the thickness of the No. 1 transfer output shaft spacer and No. 2 transfer output shaft spacer.

Minimum Thickness:

Transfer Output Shaft Spacer

Minimum Thickness

No. 1 Transfer Output Shaft Spacer

2.80 mm (0.111 in.)

No. 2 Transfer Output Shaft Spacer

4.045 mm (0.160 in.)

If the thickness is less than the minimum, replace the transfer output shaft spacer.

8. INSPECT SOLENOID COIL SUB-ASSEMBLY

(a) Install the solenoid coil sub-assembly with the 3 nuts.

Torque:

9.5 N·m {97 kgf·cm, 84 in·lbf}

Text in Illustration

*a

Rear Transfer Case Hole

Make sure that the solenoid coil sub-assembly terminal extends out from the rear transfer case hole.

(b) Connect the solenoid coil sub-assembly terminal.

(1) Attach the claw to connect the solenoid coil sub-assembly terminal.

(2) Install the retainer to the coupler.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

2 (SCC) - Case GND

Always

1.62 to 1.78 Ω

Text in Illustration

*a

Component without harness connected

(Solenoid Coil Sub-assembly)

*b

Case GND

HINT:

For case ground, perform the measurement at one of the locations indicated by the arrows.

    Disassembly

    Installation

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