Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Some 2004 – 2009 model year Highlander, 2001 – 2005 model year RAV4, and 2004 – 2010 model year Sienna AWD (4WD) vehicles may display a transmission ?uid or gear oil seepage from a vent on the right side of the transfer case. The seepage is from the transfer RH (right-hand) bearing retainer No. 2 oil seal. Production improvements have been implemented to prevent this condition from occurring. Follow the repair procedure in this bulletin to replace the RH bearing retainer No. 2 oil seal assembly. Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD) Repair Procedure: Removal 1. Con?rm source of gear oil/transmission ?uid seepage is from vent on RH bearing retainer. 2. Remove the engine assembly with transaxle. Refer to the Technical Information System (TIS), applicable model and model year Repair Manual: • 2004 Highlander: Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE: Partial Engine Assy: Replacement” • 2005 Highlander: Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE: Partial Engine Assy: Replacement” • 2006 Highlander: Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE Engine Mechanical: Engine Assembly: Removal” • 2007 Highlander: Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE Engine Mechanical: Engine Assembly: Removal” • 2008 / 2009 Highlander: Engine/Hybrid System – Engine Mechanical – “ 2GR-FE Engine Mechanical: Engine Assembly: Removal” 3. Remove the automatic transmission w/transfer. Refer to TIS, applicable model and model year Repair Manual: • 2004 Highlander: Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Assy (U151E/U151F) / (U241E/U140F): Replacement” • 2005 Highlander: Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Assy (U151E/U151F) / (U241E/U140F): Replacement” • 2006 Highlander: Drivetrain – Automatic Transmission/Transaxle – “U140F / U151F Automatic Transaxle: Automatic Transaxle Assembly: Removal” 4. Remove the transfer case No. 1 plug and remove the gasket from the plug. 5. Remove the transfer drain plug and remove the gasket from the drain plug. 6. Remove the transfer assembly. A. Remove the 2 bolts and 6 nuts. B. Using a plastic hammer, drive out the transfer assembly from the transaxle assembly. NOTICE • Disconnect the transfer assembly from the transaxle assembly without tilting. • When moving the transfer assembly, do NOT hold the assembly by the oil seals.

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1. Raise vehicle. CAUTION: Do not allow propshafts to hang at attached end. Damage to joint can result. 2. 3. 4. 5. Remove the front and rear propeller shafts. Refer to REMOVAL . Support transmission with jack stand. Remove rear crossmember and skid plate, if equipped. Disconnect transfer case vent hose (4). See Fig. 2. 6. 7. 8. 9. 10. Disconnect the wiring connector from the shift motor, if necessary. Support transfer case with transmission jack and secure with chains. Remove nuts (2) attaching transfer case (1) to transmission (3). Pull transfer case and jack rearward to disengage transfer case. Remove transfer case from under vehicle. DISASSEMBLY TRANSFER CASE-MP140 Position transfer case on shallow drain pan. Remove drain plug (2) and drain lubricant. 2. Using Holder C-3281 (1), remove the rear output flange nut. 3. Remove the rear output shaft flange (1) from the main shaft (2). If flange is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller. Be sure puller tool is positioned securely on flange.

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Removal 1. With the vehicle in NEUTRAL, raise and support the vehicle. 2. NOTE: Drain the transfer case if disassembly is required. Remove the drain plug and drain the transfer case. 3. Remove the skid plate, if equipped. 4. NOTE: To maintain initial driveshaft balance, index-mark the rear driveshaft. Remove the rear driveshaft. For additional information, refer to Section 205-01. 5. Remove the two nuts and the front driveshaft shield. 6. NOTE: To maintain initial driveshaft balance, index-mark the front driveshaft. Remove the front driveshaft. For additional information, refer to Section 205-01. 7. Make preliminary adjustment references. 1. Index-mark the torsion bars to the torsion bar crossmember. 2. Measure and record the torsion bar adjuster bolt length. 8. Remove the bolts. 9. Using the special tools, remove the torsion bar adjustment nuts. Tighten the special tool until the torsion bar adjuster lifts off the adjuster nut. 10. Remove the torsion bar adjusting brackets. 1. Move the torsion bars forward. 2. Remove the torsion bar adjusting brackets. 11. Pull the torsion bar rearward and separate it from the lower control arm. Remove the RH torsion bar only. 12. Remove the six bolts and the torsion bar crossmember.

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The A4WD system is an electronic shift 4×4 system that allows the operator to choose between three different 4×4 modes as well as 2-wheel drive. The operator can switch between 2WD, A4WD, and 4WD HIGH modes at speed. To engage or disengage LOW Range, the vehicle speed must be less than 5 kph, the brake depressed, and the transmission must be in NEUTRAL. A4WD In A4WD, the generic electronic module (GEM) varies the torque split between front and rear drivelines by controlling the transfer case clutch. Under most conditions, the GEM activates the transfer case clutch at a minimum duty cycle (percentage of time the clutch is turned on) which allows for slight speed differences between the front and rear driveshafts which normally occurs when negotiating a corner on dry pavement. When the rear wheels are overpowered, the GEM detects this slip condition, and the duty cycle to the transfer case clutch is increased until the speed difference between driveshafts is reduced. In this manner, the GEM can redirect up to 50% of engine torque to the front wheels when the rear wheels lose traction, yet still allow operation in the A4WD mode on dry pavement without driveline wind-up. NOTE: When the ABS system is active, the GEM will default to a minimum duty cycle for the transfer case clutch. Feature Inputs: 4WD mode switch (various resistances). Front/rear driveshaft speed sensors (Hall effect sensor output: 26.67 Hz/mph). ABS active input (battery voltage when ABS is active, grounded when inactive). Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open). Feature Outputs: Solid state clutch relay output (pulse width modulated signal: grounded when relay is on, battery potential when relay is off). 4×2/4×4 vacuum solenoid (ground when activated, open circuit when deactivated). A4WD indicator (ground when activated, open circuit when deactivated). Shifting Between 2WD, A4WD, and 4WD HIGH Shifts between 2WD, A4WD, and 4WD HIGH can be made at any speed. Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes. Feature Inputs: 4WD mode switch (various resistances). Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open:). Feature Outputs: 4×4 shift motor relay outputs. Solid state clutch relay (pulse width modulated signal; grounded when relay is on, battery potential when relay is off). 4×2/4×4 vacuum solenoid (ground when activated, open circuit when deactivated). Cluster indicators (ground when activated, open circuit when deactivated). Shifting Into/Out of LOW RANGE When shifting into or out of LOW RANGE, the GEM requires that the vehicle speed is less than 5 kph, the brake is applied, and the transmission is in NEUTRAL. Feature Inputs: 4WD mode switch (various resistances). Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open:). VSS Sensor (sinusoid signal: 0.7V-20V, 2.2 Hz/mph). Brake input (battery voltage when brake is depressed, open circuit when not activated). Digital transmission range (DTR) sensor (ground when transmission is in neutral, open circuit otherwise). Start/clutch depressed input. Feature Outputs: 4×4 shift motor relay outputs. 4×2/4×4 vacuum solenoid (ground when activated, open circuit when deactivated). Cluster indicators (ground when activated, open circuit when deactivated).

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All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100-02 4×4 vehicles 3. Remove the transfer case. For additional information, refer to Section 308-07A. 4. To maintain initial driveshaft balance, index-mark the front flange and pinion flange. ? Remove the four bolts and remove the front driveshaft. 4×2 vehicles 5. Remove the rear driveshaft. For additional information, refer to Section 205-01. All vehicles 6. NOTE: Drain the transmission fluid if the transmission is disassembled, or installation of a new transmission is necessary. Place a drain pan under the transmission fluid pan. 7. Drain the transmission fluid. Loosen the transmission fluid pan bolts and allow the fluid to drain. After the fluid has drained, remove the bolts. Remove the transmission fluid pan and transmission fluid pan gasket. 9. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. 1. Position the transmission fluid pan gasket. 2. Position the transmission fluid pan. 10. Install the bolts. 11. Remove the starter motor solenoid terminal cover. 12. NOTE: The 4.6L engine is shown, the 4.2L and 5.4L engines are similar. Disconnect the starter motor electrical connectors. 4.2L engines 13. Remove the bolt, stud bolt and starter. 4.6L and 5.4L engines 14. Remove the starter motor. 1. Remove the stud bolt. 2. Remove the two bolts. 3. Remove the starter.