Toyota 4Runner: Disassembly

DISASSEMBLY

PROCEDURE

1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY IN PLACE

(a) Fix the rear differential carrier assembly to the overhaul attachment.

2. INSPECT REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR

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

3. INSPECT RUNOUT OF DIFFERENTIAL RING GEAR

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

Maximum runout:

0.07 mm (0.00276 in.)

If the runout is more than the maximum, replace the ring gear with a new one.

4. 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 performs repairs as necessary.

5. INSPECT DIFFERENTIAL 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):

0.88 to 1.98 N*m (8.97 to 20.2 kgf*cm, 7.79 to 17.5 in.*lbf)

If necessary, disassemble and inspect the differential assembly.

6. INSPECT TOTAL PRELOAD

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

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

Standard total preload (at starting):

Drive pinion preload plus 0.20 to 0.40 N*m (2.0 to 4.1 kgf*cm, 1.8 to 3.5 in.*lbf)

If necessary, disassemble and inspect the differential.

7. REMOVE DIFFERENTIAL LOCK SHIFT ACTUATOR

(a) Remove the 4 bolts and actuator from the differential carrier.

(b) Remove the O-ring.

8. REMOVE DIFFERENTIAL LOCK INDICATOR SWITCH

(a) Remove the indicator switch and gasket.

9. REMOVE REAR DIFFERENTIAL LOCK SHIFT FORK SHAFT

(a) Using a 6 mm hexagon wrench, remove the 2 screw plugs.

(b) Remove the spring seat, spring and ball.

(c) Using a 5 mm pin punch and hammer, remove the slotted pin.

(d) Remove the 2 bolts from the shaft retainer.

(e) Using a plastic-faced hammer, remove the shaft retainer.

(f) Remove the shift fork shaft.

(g) Remove the rear differential lock sleeve.

10. REMOVE REAR DRIVE PINION NUT

(a) Using SST and a hammer, loosen the staked part of the nut.

SST: 09930-00010

(b) Use SST to hold the drive pinion companion flange. SST: 09330-00021

(c) Using a 30 mm socket wrench, remove the rear drive pinion nut.

11. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR

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

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03040

NOTICE:

Apply grease to the threads and tip of the SST center bolt before use.

12. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

(a) Using SST, remove the oil seal from the differential carrier.

SST: 09308-10010

13. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

NOTICE:

Apply grease to the threads and tip of the SST center bolt before use.

14. REMOVE REAR DRIVE PINION FRONT BEARING (INNER)

(a) Using SST, remove the drive pinion tapered roller bearing from the drive pinion.

SST: 09556-22010

NOTICE:

Apply grease to the threads and tip of the SST center bolt before use.

15. REMOVE REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK

(a) Remove the 2 bolts and 2 rear differential bearing adjusting nut locks.

16. REMOVE DIFFERENTIAL CASE ASSEMBLY

(a) Place matchmarks on the bearing cap and differential carrier.

Text in Illustration

*a

Matchmark

(b) Remove the 4 bolts and 2 differential bearing caps.

(c) Remove the 2 adjusting nuts.

(d) Remove the rear differential case sub-assembly and 2 case bearings from the differential carrier. HINT: Tag the 2 case bearing outer races so that they can be reinstalled in the correct locations.

17. REMOVE DIFFERENTIAL DRIVE PINION

(a) Remove the differential drive pinion and bearing spacer from the differential carrier.

18. REMOVE REAR DRIVE PINION REAR BEARING (INNER)

(a) Using SST and a press, remove the drive pinion tapered roller bearing from the drive pinion.

SST: 09950-00020

NOTICE:

Do not drop the drive pinion.

HINT:

If either the drive pinion or ring gear is damaged, replace them as a set.

19. REMOVE REAR DRIVE PINION REAR BEARING (OUTER)

(a) Using a brass bar and hammer, remove the rear tapered roller bearing from the carrier.

HINT:

If the bearing is damaged during the removal, replace it.

20. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

21. REMOVE DIFFERENTIAL RING GEAR

(a) Place matchmarks on the ring gear and differential case.

Text in Illustration

*a

Matchmark

(b) Using a screwdriver and hammer, unstake the lock plates.

(c) Remove the 12 ring gear set bolts.

(d) Using a plastic-faced hammer, tap on the ring gear to separate it from the differential case.

22. REMOVE REAR DRIVE PINION FRONT BEARING (OUTER)

(a) Using SST, remove the front tapered roller bearing from the carrier.

SST: 09308-00010

(b) Using a brass bar and hammer, remove the oil storage ring from the carrier.

HINT:

If the bearing is damaged during the removal, replace it.

23. INSPECT DIFFERENTIAL CASE ASSEMBLY RUNOUT

(a) Install the rear differential case bearing to the differential case.

(b) Install the differential case to the differential carrier.

(c) Install the 2 bearing caps to the differential carrier with the 4 bolts.

Torque:

103 N·m {1050 kgf·cm, 76 ft·lbf}

(d) Inspect the differential case runout.

Maximum runout:

0.07 mm (0.00276 in.)

(e) Remove the differential case.

(f) Remove the rear differential case bearing.

24. REMOVE REAR DIFFERENTIAL CASE BEARING

(a) Using SST, remove the 2 rear differential case bearings from the differential case.

SST: 09950-40011

09953-04020

09951-04010

09952-04010

09954-04010

09955-04061

09957-04010

09958-04011

SST: 09950-60010

09951-00500

09951-00650

09952-06010

25. DISASSEMBLE DIFFERENTIAL CASE

(a) Place matchmarks on the LH and RH cases.

Text in Illustration

*a

Matchmark

(b) Remove the 8 bolts.

(c) Using a plastic-faced hammer, separate the LH and RH cases.

(d) Remove the parts shown in the illustration from the differential case. Text in Illustration *1 Side Gear *2 Side Gear Thrust Washer *3 Spider *4 Pinion Gear *5 Pinion Gear Thrust Washer