Toyota 4Runner: Disassembly

DISASSEMBLY

PROCEDURE

1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY IN PLACE

2. INSPECT RUNOUT OF 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

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.)

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.)

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.

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 1.08 to 2.38 N*m (11.0 to 24.3 kgf*cm, 9.6 to 21.0 in.*lbf)

If necessary, disassemble and inspect the differential.

7. REMOVE REAR DRIVE PINION NUT

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

SST: 09930-00010

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

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

8. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using SST, remove the rear drive pinion companion flange sub-assembly.

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.

9. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

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

SST: 09308-10010

10. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

11. REMOVE REAR DRIVE PINION FRONT BEARING (INNER)

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

SST: 09556-22010

12. REMOVE DIFFERENTIAL CASE ASSEMBLY

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

Text in Illustration

*1

Matchmark

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

(c) Using a screwdriver and hammer, remove the 2 plate washers. HINT: Measure the plate washer thickness and note it down.

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

13. REMOVE DIFFERENTIAL DRIVE PINION

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

14. REMOVE REAR DRIVE PINION REAR BEARING

(a) Using SST and a press, press out the roller bearing (inner) from the drive pinion.

SST: 09950-00020

NOTICE:

Do not drop the drive pinion.

HINT:

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

15. REMOVE REAR DRIVE PINION FRONT BEARING (OUTER)

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

SST: 09308-00010

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

HINT:

If the bearing is damaged during removal, replace it.

16. REMOVE REAR DRIVE PINION REAR BEARING

(a) Using SST, tap out the rear tapered roller bearing (outer) from the carrier.

SST: 09308-00010

HINT:

If the bearing is damaged during removal, replace it.

17. REMOVE REAR DIFFERENTIAL DRIVE PINION PLATE WASHER

18. REMOVE DIFFERENTIAL RING GEAR

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

Text in Illustration

*a

Matchmark

(b) Remove the 12 ring gear set bolts.

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

19. 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 (1049 kgf*cm, 76 ft.*lbf)

(d) Using a dial indicator, measure the differential case runout.

Maximum runout:

0.07 mm (0.00276 in.)

(e) Remove the differential case.

(f) Remove the rear differential case bearing.

20. REMOVE REAR DIFFERENTIAL CASE BEARING

(a) Using SST, remove the 2 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

NOTICE:

Do not remove a case bearing unless replacing the differential case.

21. DISASSEMBLE DIFFERENTIAL CASE

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

Text in Illustration

*1

Matchmark

(b) Remove the 8 bolts.

NOTICE:

Loosen the bolts, diagonally opposite of each other, in pairs.

(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