Toyota Tundra. Manual — part 2931

Fig. 66: Pressing In Drive Clutch Hub Using SST
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. INSTALL FRONT DRIVE CLUTCH SLEEVE

a. Apply gear oil to the connecting areas of the clutch sleeve and clutch hub.

b. Install the drive clutch sleeve onto the rear output shaft.

Fig. 67: Identifying Drive Clutch Sleeve
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Install the 3 No. 1 synchromesh shifting keys and 2 No. 1 synchromesh shifting key springs.

NOTE:

Make sure that the clutch sleeve is installed facing the correct
direction.

NOTE:

Install the key springs so that their end gaps are not aligned.

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra

Fig. 68: Installing Synchromesh Shifting Keys
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

3. INSTALL TRANSFER SYNCHRONIZER RING SET

a. Install the outer synchronizer ring onto the rear output shaft.

Fig. 69: Identifying Outer Synchronizer Ring
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Install the center synchronizer ring onto the rear output shaft.

Fig. 70: Identifying Center Synchronizer Ring
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Install the inner synchronizer rings onto the rear output shaft.

NOTE:

Align the slots of the outer synchronizer ring with the shifting keys.

NOTE:

Align the slots of the outer synchronizer ring with those of the inner
rings.

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra

Fig. 71: Identifying Inner Synchronizer Rings
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

4. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

a. Install a new drive sprocket bearing.

Fig. 72: Identifying Drive Sprocket Bearing
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Install the drive sprocket.

Fig. 73: Identifying Drive Sprocket
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Align the cutouts in the drive sprocket with the protrusions on the
center synchronizer ring.

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra

5. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING

a. Using SST and a press, press in a new bearing.

SST 09316-60011 (09316-00011)

Fig. 74: Pressing In Bearing Using SST
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

6. INSPECT TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

a. Using a feeler gauge, measure the drive sprocket thrust clearance.

Standard clearance: 0.10 to 0.26 mm (0.00394 to 0.0102 in.)

Maximum clearance: 0.26 mm (0.0102 in.)

If the clearance is greater than the maximum, replace the drive sprocket sub-assembly.

Fig. 75: Measuring Drive Sprocket Thrust Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:

Make sure the bearing is installed in the correct direction.

2009 Toyota Tundra

2009 TRANSMISSION JF1A Transfer - Tundra