Differential: Removal & Installation Toyota 4Runner IV рестайлинг

REMOVAL

1. REMOVE FRONT WHEELS
2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY Remove the 6 bolts and engine under cover assembly.
3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Remove the 4 bolts and No. 1 engine under cover sub-assembly.
4. DRAIN DIFFERENTIAL OIL (See «DIFFERENTIAL OIL»(ref-280538-S39972817262008022200000) )
5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See «REMOVAL»(ref-280559-S10121712372008022200000) )
6. REMOVE FRONT AXLE HUB LH NUT (See «REMOVAL»(ref-280579-S10736374262008022200000) )
7. REMOVE FRONT AXLE HUB RH NUT HINT: Use the same procedure as for the LH side.
8. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH (See «REMOVAL»(ref-280558-S35656230792008022200000) )
9. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure as for the LH side.
10. SEPARATE FRONT SPEED SENSOR LH (See «REMOVAL»(ref-280578-S03216819242008022200000) )
11. SEPARATE FRONT SPEED SENSOR RH HINT: Use the same procedure as for the LH side.
12. SEPARATE TIE ROD SUB-ASSEMBLY LH (See «REMOVAL»(ref-280575-S22337806492008022200000) )
13. SEPARATE TIE ROD SUB-ASSEMBLY RH (See «REMOVAL»(ref-280575-S22337806492008022200000) )
14. REMOVE NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH (See «REMOVAL»(ref-280558-S16403555632008022200000) )
15. REMOVE NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER RH HINT: Use the same procedure as for the LH side.
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See «REMOVAL»(ref-280577-S23039306102008022200000) )
17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See «REMOVAL»(ref-280577-S23039306102008022200000) )
18. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY Remove the bolt and separate the front differential breather tube bracket. Support the front differential with a jack. Remove the front differential mount nut No. 1. Remove the 2 front mounting bolts and 2 nuts. Lower the jack and remove the front differential assembly. Remove the 2 bolts and No. 3 front differential support. Remove the 5 bolts and 2 front differential supports. see scheme 86: Locating Front Differential Carrier Assembly Bolts

Scheme 107

1. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY Remove the 4 bolts. Using a plastic hammer, remove the differential tube. (Scheme 107): Removing Differential Tube
2. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL Using SST, remove the oil seal. SST 09308-00010 see scheme 88: Removing Oil Seal
3. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY Using SST and a hammer, remove the nut. SST 09930-00010 see scheme 89: Removing Nut Using SST to hold the companion flange, remove the nut. SST 09330-00021(09330-00030) see scheme 90: Removing Nut Using SST, remove the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) see scheme 91: Removing Companion Flange
4. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL Using SST, remove the oil seal from the differential carrier assembly. SST 09308-10010
5. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER see scheme 92: Removing Oil Seal From Differential Carrier Assembly
6. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING Using SST, remove the rear bearing from the drive pinion. SST 09556-22010 Remove the bearing spacer.
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER Using a screwdriver, remove the union. Remove the 10 bolts and tap out the side bearing retainer with a plastic hammer. see scheme 93: Removing Union
8. REMOVE DIFFERENTIAL CASE ASSEMBLY
9. REMOVE DIFFERENTIAL DRIVE PINION
10. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING Using SST and a press, remove the front bearing and washer from the drive pinion. SST 09950-00020 HINT: If the drive gear or ring gear is damaged, replace them as a set. see scheme 94: Removing Front Bearing And Washer From Drive Pinion
11. REMOVE FRONT BEARING OUTER RACE Using a brass bar and a hammer, remove the front bearing outer race. see scheme 95: Removing Front Bearing Outer Race
12. REMOVE REAR BEARING OUTER RACE Using SST, remove the rear bearing outer race. SST 09502-12010, 09612-65014 (09612-01020, 09612-01050) Using a brass bar and a hammer, remove the oil storage ring.
13. REMOVE SIDE BEARING OUTER RACE HINT: Measure the plate washer and note its thickness. Tag the bearing outer races to show the location for reassembly. see scheme 96: Removing Rear Bearing Outer Race Using SST and a press, remove the outer race and plate washer from the bearing retainer. SST 09950-60020 (09951 -00680), 09950-70010 (09951-07150) see scheme 97: Removing Outer Race And Plate Washer From Bearing Retainer Using SST and a press, remove the outer race and plate washer from the differential carrier assembly. SST 09950-60020 (09951 -00680), 09950-70010 (09951-07150)
14. REMOVE DIFFERENTIAL RING GEAR Place matchmarks on the ring gear and differential case assembly. Remove the 10 bolts. Using a plastic hammer, tap on the ring gear to separate it from the differential case assembly. see scheme 98: Identifying Matchmarks On Ring Gear And Differential Case Assembly
15. REMOVE FRONT DIFFERENTIAL CASE BEARING Using SST, remove the 2 differential case bearings from the differential case assembly. SST 09950-60010 (09951-00390), 09950-40011 (09951*04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011) HINT: Fix the claws of SST into the notch in the differential case assembly. see scheme 99: Removing Differential Case Bearings From Differential Case Assembly
16. DISASSEMBLE DIFFERENTIAL CASE Using a pin punch and a hammer, remove the, straight pin. Remove these parts from the differential case assembly. 2 Differential side gears 2 Differential side gear thrust washers Differential pinion shaft 2 Differential pinion gears 2 Differential pinion gear thrust washers see scheme 100: Removing Straight Pin
17. INSPECT DIFFERENTIAL GEAR KIT Check that there is no damage to the pinion gear and side gear. If the pinion gear and/or side gear is damaged, replace the differential gear kit.
18. INSPECT FRONT DIFFERENTIAL CASE Check that the differential case assembly is not damaged. If the differential case assembly is damaged, replace it.
19. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL Using SST, remove the oil seal from the differential tube. SST 09308-00010 see scheme 101: Removing Oil Seal From Differential Tube
20. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH Using a snap ring expander, remove the snap ring. Remove the side gear shaft from the differential tube. see scheme 102: Removing/Installing Snap Ring
21. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING Using a snap ring expander, remove the snap ring. Using SST, a brass bar and a press, remove the bearing. SST 09950-00020 NOTE: Do not damage the bearing. see scheme 103: Removing Bearing And Snap Ring
22. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR Using SST, a socket wrench and a press, remove the dust deflector. SST 09950-00020 see scheme 104: Removing Dust Deflector

INSTALLATION

1. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY Install the No. 1 mounting support with the 3 bolts. Torque: 186 N*m (1,900 kgf*cm, 137 ft.*lbf) Install the No. 2 mounting support with the 2 bolts. Torque: 160 N*m (1,630 kgf*cm, 118 ft.*lbf) Install the No. 3 front differential support with the 2 bolts. Torque: 108 N*m (1,100 kgf*cm, 80 ft.*lbf) Support the front differential with a jack. Install the 2 front mounting bolts and nuts. Torque: 137 N*m (1,400 kgf*cm, 101 ft.*lbf) Install the No. 1 front differential mount nut. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) see scheme 136: Locating Mounting Support Bolts Install the front differential breather tube bracket with the bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) Lower the jack.
2. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See «INSTALLATION»(ref-280577-S35218572972008022200000) )
3. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH HINT: Use the same procedure as for the LH side.
4. INSTALL NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH (See «INSTALLATION»(ref-280558-S10625450682008022200000) )
5. INSTALL NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER RH
6. INSTALL TIE ROD END SUB-ASSEMBLY LH (See «INSTALLATION»(ref-280575-S35587798372008022200000) )
7. INSTALL TIE ROD END SUB-ASSEMBLY RH (See «INSTALLATION»(ref-280575-S35587798372008022200000) )
8. INSTALL FRONT SPEED SENSOR LH (See «INSTALLATION»(ref-280578-S12234472352008022200000) )
9. INSTALL FRONT SPEED SENSOR RH HINT: Use the same procedure as for the LH side.
10. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See «INSTALLATION»(ref-280558-S36510890452008022200000) )
11. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure as for the LH side.
12. INSTALL FRONT AXLE HUB LH NUT (See «INSTALLATION»(ref-280579-S30931584142008022200000) )
13. INSTALL FRONT AXLE HUB RH NUT HINT: Use the same procedure as for the LH side.
14. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (See «INSTALLATION»(ref-280559-S28927078652008022200000) )
15. FILL UP DIFFERENTIAL OIL (See «DIFFERENTIAL OIL»(ref-280538-S39972817262008022200000) )
16. INSPECT DIFFERENTIAL OIL (See «DIFFERENTIAL OIL»(ref-280538-S39972817262008022200000) )
17. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Install the No. 1 engine under cover sub-assembly with the 4 bolts.
18. INSTALL REAR ENGINE UNDER COVER ASSEMBLY Install the engine under cover assembly rear with the 6 bolts.
19. INSTALL FRONT WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf)
20. INSPECT CHECK ABS SENSOR SIGNAL HINT: (See «TEST MODE PROCEDURE»(ref-280578-S38790028822008022200000) )

1. REMOVE REAR WHEEL
2. SEPARATE PROPELLER SHAFT ASSEMBLY See procedure VEHICLE TYPE CHART Vehicle Type Proceed to 2WD «REMOVAL»(ref-280559-S23549980282008022200000) 4WD «REMOVAL»(ref-280559-S07613221082008022200000)
3. DRAIN DIFFERENTIAL OIL (See «DIFFERENTIAL OIL»(ref-280538-S39972817262008022200000) )
4. SEPARATE REAR SPEED SENSOR LH (See «REMOVAL»(ref-280578-S08134128162008022200000) )
5. SEPARATE REAR SPEED SENSOR RH HINT: Use the same procedure as for the LH side.
6. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY LH Remove the 2 bolts and separate the rear disc brake caliper assembly LH. HINT: Do not disconnect the flexible hose from the disc brake caliper assembly LH.
7. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY RH Remove the 2 bolts and separate the rear disc brake caliper assembly RH. HINT: Do not disconnect the flexible hose from the disc brake caliper assembly RH.
8. REMOVE REAR DISC (See «DISASSEMBLY»(ref-280540-S33333095512008022200000) )
9. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (See «DISASSEMBLY»(ref-280541-S33592555242008022200000) )
10. REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING (See «DISASSEMBLY»(ref-280541-S33592555242008022200000) )
11. REMOVE PARKING BRAKE SHOE STRUT LH
12. REMOVE PARKING BRAKE SHOE
13. REMOVE REAR AXLE SHAFT WITH BACKING PLATE (See «REMOVAL»(ref-280579-S15324874212008022200000) )
14. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY Remove the 10 nuts, 10 washers and differential carrier assembly. NOTE: Be careful not to damage the contact surfaces of the differential carrier and rear axle housing.

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

1. REMOVE REAR DIFFERENTIAL CARRIER GASKET
2. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY (Scheme 108): Locating Rear Differential Carrier Assembly Bolts
3. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR Using a dial indicator, measure the runout of the companion flange vertically and horizontally. Maximum runout: Vertical runout: 0.10 mm (0.0039 in.) Lateral runout: 0.10 mm (0.0039 in.) If the runouts are not with the specifications, replace the companion flange. (Scheme 109): Measuring Runout Of Companion Flange
4. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Using a dial indicator, check the runout of the ring gear. Maximum runout: 0.07 mm (0.0028 in.) If the runout is greater than the maximum, replace the ring gear with a new one. (Scheme 110): Checking Runout Of Ring Gear
5. INSPECT DIFFERENTIAL RING GEAR BACKLASH Using a dial indicator, check the backlash of the ring gear. Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) If the backlash is not within the specification, adjust or repair the side bearing preload as necessary. (Scheme 111): Checking Backlash Of Ring Gear
6. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting): 0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 5.0 to 7.5 in.*lbf) If necessary, disassemble and inspect the differential assembly. HINT: Before measurement, rotate the ring gear 5 times or more. (Scheme 112): Measuring Preload Of Backlash Between Drive Pinion And Ring Gear
7. INSPECT TOTAL PRELOAD Using a torque wrench, measure the total preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.39 to 0.59 N*m (4.0 to 6.0 kgf*cm, 3.5 to 5.2 in.*lbf) If necessary, disassemble and inspect the differential. see scheme 145: Measuring Preload With Teeth Of Drive Pinion And Ring Gear In Contact
8. REMOVE REAR DRIVE PINION NUT 2WD drive type: Using a "Tone" socket (E10), remove the 4 stud bolts. Using SST and a hammer, unstake nut. SST 09930-00010 (Scheme 113): Unstaking Nut Using SST to hold the drive pinion companion flange, remove the nut. SST 09330-00021 (09330-00030) (Scheme 114): Holding Drive Pinion Companion Flange
9. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR Using SST, remove the drive pinion companion flange. SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03030,09956-03030) (Scheme 115): Removing Drive Pinion Companion Flange
10. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL Using SST, remove the oil seal from the differential carrier. SST 09308-10010
11. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER see scheme 149: Removing Oil Seal From Differential Carrier Assembly
12. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Using SST, remove the front bearing from the drive pinion. SST 09556-22010 see scheme 150: Removing Union
13. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK Remove the 2 bolts and 2 rear differential bearing adjusting nut locks. (Scheme 116): Locating Rear Differential Bearing Adjusting Nut Locks And Bolts
14. REMOVE DIFFERENTIAL CASE ASSEMBLY Place matchmarks on the bearing cap and differential carrier. Remove the 4 bolts and 2 differential bearing caps. Remove the 2 adjusting nuts. (Scheme 117): Identifying Matchmarks On Bearing Cap And Differential Carrier Remove the rear differential case assembly and 2 bearing outer races from the differential carrier assembly. HINT: Tag the 2 bearings outer races to show the locations for reassembly. (Scheme 118): Removing Rear Differential Case Assembly And Bearing Outer Races
15. REMOVE DIFFERENTIAL DRIVE PINION Remove the differential drive pinion and bearing spacer from the differential carrier assembly. (Scheme 119): Identifying Differential Drive Pinion
16. REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING Using SST and a press, remove the rear bearing from the drive pinion. SST 09950-00020 HINT: If either the drive pinion or ring gear is damaged, replace them as a set. (Scheme 120): Removing Rear Bearing From Drive Pinion
17. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER Remove the plate washer from the drive pinion.
18. REMOVE FRONT BEARING OUTER RACE Using a brass bar an a hammer, remove the front bearing outer race from the differential carrier assembly.
19. REMOVE DIFFERENTIAL OIL STORAGE RING Using a brass bar and a hammer, remove the oil storage ring. (Scheme 121): Removing Oil Storage Ring
20. REMOVE REAR BEARING OUTER RACE Using a brass bar and a hammer, remove the rear tapered roller bearing from the carrier. (Scheme 122): Removing Rear Tapered Roller Bearing From Carrier
21. REMOVE DIFFERENTIAL RING GEAR Place matchmarks on the ring gear and differential case assembly. Using a screwdriver and a hammer, unstake the 5 lock plates. Remove the 10 ring gear set bolts and 5 lock plates. Using a plastic hammer, tap on the ring gear to separate it from the differential case assembly. (Scheme 123): Unstaking Lock Plates
22. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT HINT: It will be done only when it exceeds the limit at the ring gear runout check. Install the differential case assembly to the differential carrier assembly. Align the matchmarks, install the 2 bearing caps with the 4 bolts to the differential carrier assembly. Torque: 85 N*m (867 kgf*cm, 63 ft*lbf) Inspect the differential case runout. Maximum runout: 0.07 mm (0.0028 in.) Remove the 4 bolts and bearing caps from the differential carrier assembly. Remove the differential case assembly from the differential carrier assembly. (Scheme 124): Inspecting Differential Case Runout
23. REMOVE REAR DIFFERENTIAL CASE BEARING Using SST, remove the 2 rear differential case bearings from the differential case assembly. SST 09950-40011(09951-04010,09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00480), 09950-60020 (09951-00730) HINT: Fix the claws of SST to the notches in the differential case assembly. (Scheme 125): Removing Rear Differential Case Bearings From Differential Case Assembly
24. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR Using SST and a press, remove the dust deflector. SST 09950-60010 (09951 -00380), 09950-70010 (09951-07150), 09950-00020 (Scheme 126): Removing Dust Deflector
25. DISASSEMBLE DIFFERENTIAL CASE Place matchmarks on the LH and RH cases. Remove the 8 bolts uniformly, a little at a time. Using a plastic hammer, separate the LH and RH cases. (Scheme 127): Identifying Matchmarks On LH And RH Cases Remove these parts from the differential case. DIFFERENTIAL CASE REFERENCE CHART A (2 pieces) Side gear B (2 pieces) Side gear thrust washer C Spider D (4 pieces) Pinion gear E (4 pieces) Pinion gear thrust washer
26. INSPECT DIFFERENTIAL PINION AND SIDE GEAR Check that there is no damage to the differential pinion and differential side gear. If the differential pinion and/or differential side gear is damaged, replace the differential. (Scheme 128): Identifying Differential Case Components

1. INSTALL DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY Remove the any oil FIPG material and be careful not to drop oil on the contact surfaces of the actuator and clutch case. Clean connecting surfaces of any residual FIPG material using gasoline or alcohol. Apply FIPG to the differential tube, as shown. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent HINT: Install the actuator within 10 minutes after applying FIPG. see scheme 209: Identifying FIPG Material Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene. Install the differential vacuum actuator assembly to the differential tube. Apply adhesive to 2 to 3 threads of the bolts end. Adhesive: Part No. 08833-00070, THREE BOND 1281 or equivalent Install the 4 bolts. Torque: 21 N*m (210 kgf*cm, 15 ft.*lbf) see scheme 210: Locating Differential Vacuum Actuator Assembly Bolts Connect the actuator hose and connector. Install the No. 1 mounting support with the 3 bolts. Torque: 186 N*m (1,900 kgf*cm, 137 ft.*lbf) Install the No. 2 mounting support with the 2 bolts. Torque: 160 N*m (1,630 kgf*cm, 118 ft.*lbf) Install the front differential support No. 3 with the 2 bolts. Torque: 108 N*m (1,100 kgf*cm, 80 ft.*lbf) Support the front differential with a jack. Install the 2 front mounting bolts and nuts. Torque: 137 N*m (1,400 kgf*cm, 101 ft.*lbf) Install the front differential mount nuts No. 1. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) Install the front differential breather tube bracket with a bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) Lower the jack. see scheme 211: Locating Mounting Support Bolts
2. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (See «INSTALLATION»(ref-280559-S28927078652008022200000) )
3. INSPECT DIFFERENTIAL OIL (See «DIFFERENTIAL OIL»(ref-280538-S39972817262008022200000) )
4. INSPECT AND ADJUST DIFFERENTIAL OIL (See «DIFFERENTIAL OIL»(ref-280538-S39972817262008022200000) )
5. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Install the engine under cover sub-assembly No. 1 with the 4 bolts.
6. INSTALL ENGINE UNDER COVER ASSEMBLY REAR Install the engine under cover assembly rear with the 6 bolts.