Lexus Car ES, IS, LS 1998-06

Transfer Case Removal & Installation

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Click image to see an enlarged view

Fig. Exploded view of the transfer case assembly-IS 250 with AWD



Click image to see an enlarged view

Fig. Exploded view of the transfer case assembly (cont.)-IS 250 with AWD

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
  4.  
  5. Remove or disconnect the following:

    Automatic transmission assembly
     
    Transfer case oil pan
     

  6.  
  7. Remove the transfer valve body assembly as follows:
    1. Remove the 4 bolts and the transfer valve body assembly
    2.  
    3. Disconnect the transfer wire connector from the transfer control solenoid.
    4.  
    5. Remove the bolt and the transfer wire.

      Transfer extension housing using SST 09950-40011
       
      8 bolts (in order), clamp and transfer case. Use a plastic hammer to tap the transfer case to remove it.
       
      Transfer rear output shaft assembly
       

    6.  

  8.  
  9. Remove the flange yoke as follows:
    1. Using a hammer and SST 09930-00010, release the staked part of the nut.
    2.  
    3. Using SST 09330-00021 and 09213-54015, hold the yoke.
    4.  
    5. Remove the nut and the flange yoke.

      10 bolts and rear transfer chain case. Use a plastic hammer to tap the rear transfer chain case to remove it.
       
      Transfer front drive chain, transfer drive sprocket and transfer front driven clutch sleeve
       
      6 bolts (in order) and front transfer chain case. Use a plastic hammer to tap the front transfer chain case to remove it.
       

    6.  

  10.  

To install:

  1. Install front transfer chain case as follows:
    1. Clean the front mating surface of any residual sealant.
    2.  
    3. Apply new sealant in a width of 0.04-0.06 inches (1.0-1.5mm) all around to the front transfer chain case front mating surface.
    4.  
    5. Temporarily tighten the 6 bolts in several steps, and then tighten them to 25 ft. lbs. (34 Nm).
    6.  

  2.  
  3. Install or connect the following:

    Transfer front drive chain, transfer drive sprocket and transfer front driven clutch sleeve
     

  4.  
  5. Install rear transfer chain case as follows:
    1. Clean the front mating surface of any residual sealant.
    2.  
    3. Apply new sealant in a width of 0.04-0.06 inches (1.0-1.5mm) all around to the rear transfer chain case front mating surface.
    4.  
    5. Temporarily tighten the 10 bolts in several steps, and then tighten them to 25 ft. lbs. (34 Nm). Tighten the bolt in the middle of the case cover to 42 ft. lbs. (57 Nm).
    6.  

  6.  
  7. Install the flange yoke as follows:
    1. Install the flange yoke.
    2.  
    3. Using SST 09330-00021 and 09213-54015, hold the yoke.
    4.  
    5. Torque the new nut to 91 ft. lbs. (123 Nm).

      Transfer rear output shaft assembly
       
      Transfer extension housing using SST 09950-40011
       

    6.  

  8.  
  9. Install transfer case as follows:
    1. Clean the front mating surface of any residual sealant.
    2.  
    3. Apply new sealant in a width of 0.04-0.06 inches (1.0-1.5mm) all around to the transfer case front mating surface.
    4.  
    5. Temporarily tighten the 8 bolts and clamp in several steps, and then tighten them to 25 ft. lbs. (34 Nm).
    6.  

  10.  
  11. Install the transfer valve body assembly as follows:
    1. Coat the transfer wire O-ring with ATF.
    2.  
    3. Install the transfer wire with the bolt.
    4.  
    5. Connect the transfer wire connector to the transfer control solenoid.
    6.  
    7. Install the transfer valve body assembly. Torque the 4 bolts to 87 inch lbs. (10 Nm).
    8.  

  12.  
  13. Install transfer case oil pan as follows:
    1. Clean and install the transfer case oil cleaner magnet to the pan.
    2.  
    3. Clean the pan contact surface of any residual sealant.
    4.  
    5. Apply new sealant in a width of 0.12-0.14 inches (3.0-3.5mm) all around the contact surface of the transfer case oil pan.
    6.  
    7. Temporarily tighten the 9 bolts in several steps, and then tighten them to 65 inch lbs. (7.5 Nm).

      Automatic transmission assembly
       

    8.  

  14.  

Nv147 Transfer Case



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Raise vehicle.
  4.  
  5. Remove transfer case drain plug and drain transfer case lubricant.
  6.  
  7. Mark front and rear propeller shaft yokes for alignment reference.
  8.  
  9. Support transmission with jack stand.
  10.  
  11. Remove rear crossmember and skid plate, if equipped.
  12.  
  13. Disconnect front propeller shaft from transfer case at companion flange. Remove rear propeller shaft from vehicle.
    NOTE
    Do not allow drive shafts to hang at attached end. Damage to joint can result.

  14.  
  15. Disconnect transfer case vent hose.
  16.  
  17. Support transfer case with transmission jack.
  18.  
  19. Secure transfer case to jack with chains.
  20.  
  21. Remove nuts attaching transfer case to transmission.
  22.  
  23. Pull transfer case and jack rearward to disengage transfer case.
  24.  
  25. Remove transfer case from under vehicle.
  26.  

To install:

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case on transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. 35 Nm).
  10.  
  11. Connect front propeller shaft and install rear propeller shaft.
  12.  
  13. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  14.  
  15. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 30 ft. lbs. (41 Nm).
  16.  
  17. Remove transmission jack and support stand.
  18.  
  19. Lower vehicle and verify transfer case shift operation.
  20.  

Nv242 Transfer Case



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Shift transfer case into NEUTRAL.
  4.  
  5. Raise vehicle.
  6.  
  7. Remove transfer case drain plug and drain transfer case lubricant.
  8.  
  9. Mark front and rear propeller shaft yokes for alignment reference.
  10.  
  11. Support transmission with jack stand.
  12.  
  13. Remove rear crossmember and skid plate, if equipped.
  14.  
  15. Disconnect front/rear propeller shafts at transfer case.
  16.  
  17. Disconnect transfer case cable from range lever.
  18.  
  19. Disconnect transfer case vent hose and transfer case position sensor.
  20.  
  21. Support transfer case with transmission jack.
  22.  
  23. Secure transfer case to jack with chains.
  24.  
  25. Remove nuts attaching transfer case to transmission.
  26.  
  27. Pull transfer case and jack rearward to disengage transfer case.
  28.  
  29. Remove transfer case from under vehicle.
  30.  

To install:

Click image to see an enlarged view

Fig. NV242 transfer case mounting points

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case on transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. (35 Nm).
  10.  
  11. Align and connect propeller shafts.
  12.  
  13. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  14.  
  15. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 30 ft. lbs. (41 Nm).
  16.  
  17. Remove transmission jack and support stand.
  18.  
  19. Connect shift rod to transfer case range lever.
  20.  
  21. Connect transfer case vent hose and transfer case position sensor.
  22.  
  23. Adjust transfer case shift cable.
  24.  
  25. Lower vehicle and verify transfer case shift operation.
  26.  

Nv247 Transfer Case



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Shift transfer case into NEUTRAL.
  4.  
  5. Raise vehicle.
  6.  
  7. Remove transfer case drain plug and drain transfer case lubricant.
  8.  
  9. Mark front and rear propeller shaft yokes for alignment reference.
  10.  
  11. Support transmission with jack stand.
  12.  
  13. Remove rear crossmember and skid plate, if equipped.
  14.  
  15. Disconnect front propeller shaft from transfer case at companion flange. Remove rear propeller shaft from vehicle.
    NOTE
    Do not allow drive shafts to hang at attached end. Damage to joint can result.

  16.  
  17. Disconnect transfer case cable from range lever.
  18.  
  19. Disconnect transfer case vent hose.
  20.  
  21. Support transfer case with transmission jack.
  22.  
  23. Secure transfer case to jack with chains.
  24.  
  25. Remove nuts attaching transfer case to transmission.
  26.  
  27. Pull transfer case and jack rearward to disengage transfer case.
  28.  
  29. Remove transfer case from under vehicle.
  30.  

To install:

Click image to see an enlarged view

Fig. NV247 transfer case mounting points

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case on transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. (35 Nm).
  10.  
  11. Connect front propeller shaft and install rear propeller shaft.
  12.  
  13. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  14.  
  15. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 30 ft. lbs. (41 nm).
  16.  
  17. Remove transmission jack and support stand.
  18.  
  19. Verify transfer case is in NEUTRAL. Connect shift cable to transfer case range lever.
  20.  
  21. Lower vehicle and verify transfer case shift operation.
  22.  
  23. Adjust the transfer case shift cable, if necessary.
  24.  

 
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