Toyota 4Runner: Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Install the rear differential side gear thrust washer to the rear differential side gear.

(b) Install the rear differential pinion thrust washer and rear differential pinion to the rear differential spider.

(c) Fix the differential case RH in place.

(d) Install the rear differential side gear and rear differential spider to the differential case RH.

(e) Using a dial indicator, measure the differential case RH side backlash while pushing the pinion toward the case. Standard backlash: 0.05 to 0.20 mm (0.00197 to 0.00787 in.)

(f) Remove the rear differential spider from the differential case RH.

(g) Install the rear differential side gear and rear differential spider to the differential case LH.

(h) Using a dial indicator, measure the differential case LH side backlash while pushing the pinion toward the case.

Backlash:

0.05 to 0.20 mm (0.00197 to 0.00787 in.)

If the backlash is not within the specification, install 2 side gear thrust washers of a different thickness.

Standard Thrust Washer:

Specified Condition	Specified Condition
0.88 to 0.92 mm (0.0346 to 0.0362 in.)	1.18 to 1.22 mm (0.465 to 0.0480 in.)
0.98 to 1.02 mm (0.0386 to 0.0402 in.)	1.28 to 1.32 mm (0.0504 to 0.00520 in.)
1.08 to 1.12 mm (0.0425 to 0.0441 in.)	-

(i) Align the matchmarks and assemble the differential case from the RH and LH cases. Text in Illustration *a Matchmark

(j) Using a plastic-faced hammer, install the differential case.

(k) Install the 8 bolts.

Torque:

47 N·m {480 kgf·cm, 35 ft·lbf}

2. INSTALL DIFFERENTIAL RING GEAR

(a) Clean the contact surfaces of the differential case and ring gear.

(b) Heat the ring gear to approximately 100°C (212°F) in boiling water.

(c) Carefully take the ring gear out of the boiling water.

(d) After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.

(e) Align the matchmarks on the ring gear and differential case. Text in Illustration *a Matchmark

(f) After the ring gear cools down sufficiently, apply adhesive to the 12 bolts and install them.

Adhesive:

Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent.

Torque:

97 N·m {985 kgf·cm, 71 ft·lbf}

3. INSTALL REAR DIFFERENTIAL CASE BEARING

(a) Using SST and a press, install the bearing to the differential case.

SST: 09308-14010

SST: 09950-60010

09951-00490

4. INSPECT DIFFERENTIAL RING GEAR RUNOUT

(a) Install the differential case to the carrier, and then install the 2 adjusting nuts so that there is no play in the bearing.

(b) Install the 2 bearing caps with the 4 bolts.

Torque:

103 N*m (1049 kgf*cm, 76 ft.*lbf)

(c) Using a dial indicator, measure the runout of the ring gear.

Maximum runout:

0.07 mm (0.00276 in.)

(d) Remove the 2 bearing caps, 2 adjusting nuts and differential case.

5. INSTALL REAR DRIVE PINION FRONT BEARING

(a) Using SST and a press, install the tapered roller bearing to the carrier.

SST: 09308-14010

SST: 09309-14040

6. INSTALL REAR DRIVE PINION REAR BEARING (OUTER)

(a) Install the plate washer to the carrier.

HINT:

First, install a washer with the same thickness as the removed washer, and then check the tooth contact pattern. Replace the washer with one of a different thickness if necessary.

(b) Using SST and a press, install the tapered roller bearing to the carrier.

SST: 09950-70010

09951-07200

SST: 09255-10012

7. INSTALL REAR DRIVE PINION REAR BEARING (INNER)

(a) Using SST and a press, install the tapered roller bearing to the drive pinion.

SST: 09506-30012

8. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD

(a) Install the drive pinion, rear drive pinion tapered roller bearing and rear differential drive oil slinger.

HINT:

Install the spacer and oil seal after adjusting the gear contact pattern.

(b) Using SST, install the drive pinion companion flange. SST: 09950-30012 09951-03010 09953-03010 09954-03010 09955-03030 09956-03040 NOTICE: Before using SST (center bolt), apply hypoid gear oil to its threads and tip.

(c) Coat the threads of the nut with hypoid gear oil LSD.

(d) Using SST to hold the drive pinion companion flange, tighten the nut. SST: 09330-00021 NOTICE: As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it. Apply hypoid gear oil to the nut. Torque: 457 N*m (4660 kgf*cm, 337 ft.*lbf) or less

(e) Using a torque wrench, measure the preload. Standard Preload (at Starting): Item Specified Condition New Bearing 0.68 to 2.03 N*m (7 to 20 kgf*cm, 7 to 17 in.*lbf) Used Bearing 0.73 to 1.83 N*m (8 to 18 kgf*cm, 7 to 16 in.*lbf) NOTICE: For a more accurate measurement, rotate the bearing forward and backward several times before measuring.

9. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Place the 2 bearing outer races on their respective bearings.

HINT:

Do not interchange the right and left races.

10. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT

(a) Install the 2 adjusting nuts to the carrier, making sure the nuts are threaded properly.

11. INSPECT AND ADJUST DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION BACKLASH

(a) Align the matchmarks on the cap and carrier.

Text in Illustration

*a

Matchmark

(b) Install the right and left bearing caps with the 4 bolts.

HINT:

If the bearing cap does not fit tightly onto the carrier, the adjusting nuts are not threaded properly.

Reinstall the adjusting nuts if necessary.

Torque:

103 N*m (1049 kgf*cm, 76 ft.*lbf)

(c) Tighten the 4 bearing cap bolts to the specified torque, and then loosen them to the point where the adjusting nuts can be turned by SST. Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) Text in Illustration *a for LH Side

(d) Using SST, tighten the adjusting nut on the ring gear side until the ring gear has a backlash of about 0.2 mm (0.008 in.).

SST: 09960-10010

09962-01000

09963-00700

(e) While turning the ring gear, use SST to tighten the adjusting nut on the drive pinion side. Text in Illustration *a for RH Side HINT: After the bearings have settled, loosen the adjusting nut on the drive pinion side.

(f) Using SST, tighten the adjusting nut 1 to 1.5 notches from the 0 preload position.

SST: 09504-00011

(g) Using a dial indicator, adjust the ring gear backlash until it is within the specification. Standard backlash (reference): 0.10 to 0.20 mm (0.00394 to 0.00787 in.) HINT: The backlash is adjusted by turning the left and right adjusting nuts an equal amount. For example, loosen the nut on the right side one notch and loosen the nut on the left side one notch. Perform the measurement at 3 or more positions around the circumference of the ring gear.

(h) Tighten the bearing cap bolts. Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) Text in Illustration *a Matchmark

12. INSPECT TOTAL PRELOAD

(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

Standard Preload (at Starting):

Item	Specified Condition
New bearing	0.88 to 2.43 N*m (9 to 24 kgf*cm, 8 to 21 in.*lbf)
Used bearing	0.93 to 2.23 N*m (10 to 22 kgf*cm, 9 to 19 in.*lbf)

If necessary, disassemble and inspect the differential.

13. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.

(b) Hold the companion flange firmly and rotate the ring gear in both directions.

(c) Inspect the tooth contact pattern.

14. REMOVE REAR DRIVE PINION NUT

(a) Using SST to hold the drive pinion companion flange, remove the nut.

SST: 09330-00021

15. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using SST, remove the drive pinion companion flange.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03040

16. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

17. REMOVE REAR DRIVE PINION FRONT BEARING (INNER)

18. REMOVE REAR DRIVE PINION FRONT BEARING (OUTER)

19. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new bearing spacer to the drive pinion.

20. INSTALL DIFFERENTIAL OIL STORAGE RING

(a) Using SST, tap in a new oil storage ring. SST: 09308-14010

21. INSTALL REAR DRIVE PINION FRONT BEARING

22. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

23. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL

(a) Apply MP grease to the oil seal lip.

(b) Using SST and a hammer, install a new carrier oil seal.

SST: 09214-76011

Standard oil seal drive in depth:

-0.3 to 0.3 mm (-0.0118 to 0.0118 in.)

Text in Illustration

*a	Oil Seal Depth

24. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR

(a) Using SST, install the drive pinion companion flange to the drive pinion.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03040

(b) Coat the threads of a new nut with hypoid gear oil.

(c) Using SST to hold the flange, tighten the nut.

SST: 09330-00021

Torque:

457 N*m (4660 kgf*cm, 337 ft.*lbf) or less

25. INSPECT DRIVE PINION PRELOAD

(a) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Standard Preload (at Starting):

Item	Specified Condition
New Bearing	0.83 to 2.18 N*m (8.64 to 22.2 kgf*cm, 7.35 to 19.3 in.*lbf)
Used Bearing	0.88 to 1.98 N*m (8.97 to 20.2 kgf*cm, 7.79 to 17.5 in.*lbf)

If the preload is more than the maximum, replace the bearing spacer.

If the preload is less than the minimum, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

Torque:

457 N*m (4660 kgf*cm, 337 ft.*lbf) or less

If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure.

HINT:

Do not loosen the pinion nut to reduce the preload.

26. INSPECT TOTAL PRELOAD

(a) Using a torque wrench, measure the preload.

If necessary, disassemble and inspect the differential.

Standard total preload (at starting):

Item	Specified Condition
New bearing	1.03 to 2.58 N*m (11 to 26 kgf*cm, 10 to 22 in.*lbf)
Used bearing	1.08 to 2.38 N*m (12 to 24 kgf*cm, 10 to 21 in.*lbf)

27. INSPECT DIFFERENTIAL RING GEAR BACKLASH

(a) Using a dial indicator, check the backlash of the ring gear.

Standard Backlash:

0.10 to 0.20 mm (0.00394 to 0.00787 in.)

If the backlash is not within the specification, adjust the side bearing preload or perform repairs as necessary.

HINT:

Perform the measurement at 3 or more positions around the circumference of the ring gear.

28. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR

(a) Using a dial indicator, measure the runout of the drive pinion companion flange vertically and laterally.

Distance from center to runout measurement point:

30 mm (1.18 in.)

Maximum Runout:

Item	Specified Condition
Vertical runout	0.10 mm (0.00394 in.)
Lateral runout	0.10 mm (0.00394 in.)

Text in Illustration

*a	Vertical Runout
*b	Lateral Runout

If the runout is more than the maximum, replace the companion flange.

29. INSTALL REAR DRIVE PINION NUT

(a) Using a chisel and hammer, stake the drive pinion nut.

30. INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK

(a) Install 2 new adjusting nut locks to the bearing caps with the 2 bolts.

Torque:

13 N*m (130 kgf*cm, 9 ft.*lbf)

(b) After tightening the bolts, bend the nut locks.

31. INSTALL REAR DIFFERENTIAL LOCK SHIFT FORK

(a) Apply MP grease to shaft.

(b) Install the fork shaft so that the hole of the shift fork shaft aligns with that of the shift fork.

Text in Illustration

*1	Holes
*2	Groove

(c) Remove any FIPG material and be careful not to drop the oil shaft retainer.

(d) Apply seal packing to the carrier as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

FIPG Width

Approx. 1 to 2 mm (0.0394 to 0.0787 in.)

Text in Illustration

*1	Seal Packing

HINT:

Install the shaft retainer within 3 minutes of applying seal packing.

(e) Clean the threads of the bolts and retainer bolt holes with toluene or trichloroethylene.

(f) Apply adhesive to 2 or 3 threads at the tip of each mount bolt.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Text in Illustration

*1

Adhesive

(g) Install the shaft retainer with the 2 bolts.

Torque:

24 N·m {240 kgf·cm, 17 ft·lbf}

(h) Using a 5 mm pin punch and hammer, install the slotted spring pin to the shift fork.

(i) Push the differential lock sleeve in deeply and hold it in position. Text in Illustration *a Lock

(j) Install the ball, spring and spring seat.

(k) Clean the threads of the 2 plugs and plug holes with toluene or trichloroethylene.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Text in Illustration

*1

Adhesive

(l) Using a 6 mm hexagon wrench, install the screw plugs.

Torque:

22 N·m {220 kgf·cm, 16 ft·lbf}

32. INSTALL DIFFERENTIAL LOCK INDICATOR SWITCH

(a) Install the indicator switch together with a new gasket.

Torque:

40 N·m {410 kgf·cm, 30 ft·lbf}

33. INSPECT REAR DIFFERENTIAL LOCK SLEEVE

(a) Measure the distance between the sleeve and tip of the differential case when the differential is free, and when it is locked.

Standard distance:

Locked: 17.44 to 18.86 mm (0.687 to 0.743 in.)

Free: 32.40 to 33.90 mm (1.276 to 1.335 in.)

34. INSTALL DIFFERENTIAL LOCK SHIFT ACTUATOR

(a) Check that the outermost rack tooth of the shift fork is approximately above the center line of the actuator installation hole.

Text in Illustration

*a	Outside
*1	Shift Fork
*2	Actuator Installation Hole

(b) Make sure that the matchmarks on the pinion of the actuator are in the range of 0 to 5 degrees clockwise from the center line of the actuator. Text in Illustration *a Matchmark *b Groove NOTICE: If the matchmarks are not within this range, rotate the pinion. Do not apply positive battery voltage directly to the terminals. If the matchmarks move to the limit of rotation, stop applying electric current.

(c) Install a new O-ring to the actuator.

(d) Apply a light coat of gear oil to the O-ring.

(e) Apply MP grease to the gear.

(f) Mack sure that the outermost rack tooth of the shift fork aligns with the matchmarks on the pinion of the actuator.

(g) Install the actuator so that the knock pin on the carrier side fits into the long hole on the actuator side.

Text in Illustration

*1

Knock Pin

HINT:

Do not damage the O-ring of the actuator.

(h) Rotate the actuator counterclockwise so that the knock pin slides to the end of the hole as shown in the illustration.

(i) Install the bolts.

Torque:

27 N·m {270 kgf·cm, 20 ft·lbf}