Toyota Celica 1986-1993 Repair Guide

Transfer Unit

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REMOVAL & INSTALLATION



For ease of removal, the entire transaxle should be removed first (See Transaxle Removal under Manual Transaxle).

  1. Remove the 3 bolts and the 5 nuts.
  2.  
  3. Using a plastic hammer, remove the transfer assembly from the transaxle.
  4.  

To install:

  1. Make sure that the contact surfaces are clean and oil-free.
  2.  
  3. Apply seal packing (part No. 08826-00090 or equivalent) to the transfer and install the transfer as soon as the packing is applied.
  4.  


WARNING
Shift into 4th gear, and install the transfer assembly while turning the input shaft of the transaxle.

  1. Apply sealant (part No. 08833-00080) to the bolt threads.
  2.  
  3. Torque the 3 bolts and the 5 nuts to 51 ft. lbs. (69 Nm).
  4.  

OVERHAUL



Disassembly
  1. Remove the dynamic damper.
  2.  
  3. Remove the extension housing by removing the 4 bolts and tapping off the housing.
  4.  
  5. Remove the O-ring and the dust deflector from the extension housing.
  6.  
  7. Remove the transfer case cover and gasket.
  8.  
  9. Remove the shift lever shaft and inner lever.
  10.  
  11. Remove the transfer case upper bushing.
  12.  
  13. Remove the plug, seat, spring and locking ball. Using a magnet may be helpful.
  14.  
  15. Remove the differential lock shift fork and shaft.
  16.  
  17. Remove the side gear shaft holder by removing the oil seal, the snapring, then the holder.
  18.  
  19. Check the preload using SST 09326-20011 and a spring tension gauge. Measure the driven pinion preload of the backlash, between the driven pinion and the ring gear. At starting it should be 2-3 lbs. (9-14 Nm). Now measure the total preload. At starting it should be 1-2 lbs. (5-9 Nm). Add the driven preload.
  20.  
  21. Remove the 3 bolts and remove the transfer inspection hole cover.
  22.  
  23. Check the ring gear backlash, using a dial indicator. It should be 0.0051-0.0071 in. (0.13-0.18mm).
  24.  
  25. Check the tooth contact pattern.
  26.  
  27. Remove the driven pinion bearing cage assembly by removing the 6 bolts and tapping off with a plastic hammer. Remove the O-ring and the shim from the driven pinion bearing cage.
  28.  
  29. Remove the transfer right case by removing the 10 bolts and tapping off with a hammer.
  30.  
  31. Remove the ring gear mounting case assembly.
  32.  
  33. Using snapring pliers, remove the adjusting lock plate from the transfer right case.
  34.  
  35. Replace the extension housing oil seal, driving it to a depth of 0.043-0.075 in. (1.1-1.9mm). Coat the lip of the seal with grease.
  36.  



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Fig. Fig. 1 Transfer unit componentsCelica



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Fig. Fig. 2 Replacing transfer unit shift fork shaft oil sealCelica



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Fig. Fig. 3 Driven pinion bearing cage componentsCelica



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Fig. Fig. 4 Ring gear mounting case componentsCelica

  1. Replace the differential lock shift shaft oil seal, driving it to a depth of 0.039-0.079 in. (1.0-2.0mm). Coat the lip of the seal with grease.
  2.  
  3. Replace the shift fork shaft oil seal, driving it to a height of 0.335-0.374 in. (8.5-9.5mm). Coat the lip of the seal with grease.
  4.  



Click image to see an enlarged view

Fig. Fig. 5 Aligning the matchmarks on the right case and left caseCelica



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Fig. Fig. 6 Installing the shift lever shaft boltCelica

  1. Replace the side gear shaft holder bearing, using snapring pliers, SST 09316-60010 and a press.
  2.  
  3. Replace the transfer oil tube, installing a new cushion and torquing the bolt to 9 ft. lbs. (13 Nm).
  4.  
  5. Replace the ring gear mounting case side bearing outer race. For the right side:
    1. Using SST 09318-20010, turn the bearing adjusting nut, remove the outer race and bearing adjusting nut.
    2.  
    3. Install the bearing adjusting nut until it touches the lip of the case. If the nut is difficult to turn, use SST 09318-20010.
    4.  
    5. Using SST kit 09608-35014 and a press, install the race until it is almost touching the bearing adjusting nut.
    6.  

  6.  
  7. For the transfer left case:
    1. Using a brass bar and a hammer, drive out the bearing outer race lightly and evenly.
    2.  
    3. Remove and inspect the plate washer.
    4.  
    5. Install the plate washer, one of the same thickness as before at first.
    6.  
    7. Using SST kit 09316-60010 and a press, install the outer race.
    8.  

  8.  
  9. Measure the clearance between the differential lock shift fork and sleeve. The maximum clearance should be 0.039 in. (1.0mm).
  10.  

DISASSEMBLY OF DRIVEN PINION BEARING CAGE
  1. Unstake the locknut and remove with SST 09326-20011.
  2.  
  3. Remove the driven pinion, using a press.
  4.  
  5. Replace the driven front bearing, using a press.
  6.  
  7. Replace the front and rear bearing outer races, using a brass bar and a press.
  8.  

REASSEMBLY OF DRIVEN PINION BEARING CAGE

WARNING
Coat all of the sliding and rotating surfaces with gear oil before assembly.

  1. Install the driven pinion bearing cage, using a new bearing spacer. Insert the spacer with the smaller facing upwards.
  2.  
  3. Using a press, install the rear bearing, pressing down until the pinion can just move slightly up and down.
  4.  
  5. Adjust the driven pinion preload, using SST 09326-20011, torquing the new locknut to 72 ft. lbs. (98 Nm). Use a torque wrench with a fulcrum length of 19.69 in. (50 cm).
  6.  
  7. Using the SST and a spring tension gauge, measure the driven pinion preload.
  8.  


WARNING
Turn the driven pinion right and left 2 or 3 times to allow the bearings to settle.

  1. The preload at starting should be 4.0-6.4 lbs. with a new bearing and 1.1-2.0 lbs. with a used one. If the preload is greater than specification, replace the bearing spacer. If the preload is less, retighten the nut 5-10 degrees at a time until the proper specification is reached.
  2.  


WARNING
If the maximum torque of 159 ft. lbs. (216 Nm) is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do NOT back off the pinion nut to reduce the preload.

  1. Stake the locknut.
  2.  

DISASSEMBLY OF THE RING GEAR MOUNTING CASE
  1. Remove the mounting case side bearing, using SST 09950-20017.
  2.  
  3. Check the ring gear runout. The maximum is 0.004 in. (0.1mm). If out of specification, check the runout of the mounting case for the limit.
  4.  
  5. Remove the ring gear after placing matchmarks on both the case and the gear.
  6.  

REASSEMBLY OF THE RING GEAR MOUNTING CASE
  1. Install the ring gear, preheating it in boiling water. Wear eye protection and protective clothing.
  2.  
  3. Check the ring gear runout.
  4.  
  5. Install the mounting case side bearings, using a press.
  6.  
  7. Install the center differential control coupling.
  8.  
  9. Install the ring gear mounting right case. Torque the 12 bolts to 71 ft. lbs. (97 Nm). Align the matchmarks on the left case and connect the right case.
  10.  

Reassembly of Transfer Component Parts

WARNING
Coat all of the sliding and rotating surfaces with gear oil before assembly.

  1. Adjust the ring gear backlash:
    1. Install the adjust shim to the driven pinion bearing cage assembly, first installing a shim of the same thickness as before.
    2.  
    3. Install the driven pinion bearing cage assembly to the transfer left case.
    4.  
    5. Install and torque the 6 bolts to 29 ft. lbs. (39 Nm), but do NOT install the O-ring.
    6.  
    7. Install the ring gear mounting case assembly to the transfer left case.
    8.  
    9. Measure the ring gear backlash, which should be 0.0051-0.0071 in. (0.13-0.18mm). If necessary, replace shims. The backlash will change about 0.0008 in. (0.02mm) with each shim thickness.
    10.  

  2.  
  3. Adjust the total preload:
    1. Install the transfer right case.
    2.  
    3. Install and torque the 12 bolts to 33 ft. lbs. (44 Nm).
    4.  
    5. Adjust the total preload by tightening the bearing adjusting nut with SST 09318-20010. Measure the preload while tightening a little at a time.
    6.  
    7. Turn the output shaft back and forth several times, then check the total preload using SST 09326-20011 and a spring tension gauge. At starting it should be 2.9-3.1 lbs. (12.7-13.7 Nm) with a new bearing. With a used bearing measure the total preload. At starting it should be 1.1-2 lbs. (4.9-8.8 Nm). Add the driven preload.
    8.  
    9. When the standard value for the total preload is exceeded, remove the transfer right case, push in the adjusting nut and outer race. Again adjust the total preload.
    10.  

  4.  
  5. Check the ring gear backlash, which should be 0.0051-0.0071 in. (0.13-0.18mm). When the backlash is outside the standard value, select a different washer and adjust the backlash and the total preload.
  6.  
  7. Check the tooth contact by coating 3 or 4 teeth at 4 different positions on the ring gear with red lead and rotating it. If poor contact, select the proper shim and plate.
  8.  
  9. Remove the ring gear mounting case assembly by removing the 12 bolts and the transfer right case.
  10.  
  11. Remove the driven pinion bearing cage by removing the 6 bolts.
  12.  
  13. Install the driven pinion bearing cage assembly:
    1. Coat the O-ring with gear oil.
    2.  
    3. Install the O-ring to the driven pinion bearing cage.
    4.  
    5. Install the driven pinion bearing cage with the adjust shim (previously selected) to the transfer left case.
    6.  
    7. Install and torque the 6 bolts to 29 ft. lbs. (39 Nm).
    8.  

  14.  
  15. Install the ring gear mounting case assembly.
  16.  
  17. Install the transfer right case:
    1. Make sure that the contacting surfaces of the transfer left and right case are clean and oil-free.
    2.  
    3. Apply the seal packing (part No. 08826-00090 or equivalent) to the transfer left case and install the transfer right case as soon as the packing is applied.
    4.  
    5. Apply sealant (part No. 08833-00080 or equivalent) to the bolt threads, then install and torque the 12 bolts to 33 ft. lbs. (44 Nm).
    6.  

  18.  
  19. Check the total preload.
  20.  
  21. Using snapring pliers, install the lock plate so that the projection from the lock plate fits properly into the groove of the adjusting nut. Choose one of the two types, tightening the adjusting nut to the minimum limit.
  22.  
  23. Install the side gear shaft side gear shaft holder to the transfer right case and installing the snapring.
  24.  
  25. Install the oil seal using a brass bar and hammer and coat the lip of the seal with grease.
  26.  
  27. Install the transfer inspection hole cover, making sure that the surfaces are clean. Apply packing (part No. 08826-00090 or equivalent) and install the cover as soon as it is applied. Torque the bolts to 12 ft. lbs. (16 Nm).
  28.  
  29. Install the differential lock shift fork shaft. Torque the bolt to 12 ft. lbs. (16 Nm). Install the transfer case upper bushing, then the inner lever in the shift fork shaft groove.
  30.  
  31. Install and torque the plug to 12 ft. lbs. (16 Nm). Install the locking ball, spring, seat and plug, using a magnet. Apply sealant to the threads and torque to 18 ft. lbs. (25 Nm).
  32.  
  33. Install the transfer case cover with a new gasket and torque the bolts to 13 ft. lbs. (17 Nm). Install the bolt to the shift lever shaft and torque to 14 ft. lbs. (20 Nm).
  34.  


WARNING
The shift lever and bolt must be in the correct position, otherwise damage can result to the transaxle.

  1. Install the extension housing:
    1. Coat the O-ring with gear oil.
    2.  
    3. Install the O-ring to the extension housing.
    4.  
    5. Install the extension housing to the driven pinion bearing cage.
    6.  
    7. Install and torque the 4 bolts to 19 ft. lbs. (25 Nm).
    8.  

  2.  
  3. Install the dynamic damper and torque the 4 bolts to 19 ft. lbs. (25 Nm).
  4.  

 
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