2007 TOYOTA 4RUNNER Service Repair Manual by 163215

1. Airbags 2. Audio Visual 3. Axle 4. Brake Control 5. Brakes 6. Charging 1gr 7. Charging 2uz 8. Cooling 1gr 9. Cooling 2uz 10. Cruise Control 11. Differential 12. Driveshaft 13. Electrical Component Locations 14. Emission Control 1gr 15. Emission Control 2uz 16. Engine 1gr 17. Engine 2uz 18. Engine Control 1gr 19. Engine Control 2uz 20. Exhaust 1gr 21. Exhaust 2uz 22. Exterior 23. Fuel 1gr 24. Fuel 2uz 25. Hood Doors 26. Horns 27. Hvac 28. Ignition 1gr 29. Ignition 2uz 30. Instrument Panel 31. Intage 1gr 32. Intake 2uz 33. Interior Trim 34. Lighting 35. Lubrication 1gr 36. Lubrication 2uz

37. Mirrors 38. Navigation 39. Parking Brakes 40. Power Door Locks 41. Power Steering 42. Propeller Shaft 43. Seats 44. Service Specs 45. Starter 1gr 46. Starter 2uz 47. Steering Column 48. Sunroof 49. Suspension Control 50. Suspension 51. Windows 52. Wiper Washer 53. Wiring

2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

2008 DRIVELINE/AXLES Differential - 4Runner

DIFFERENTIAL SYSTEM PRECAUTION 1. Before disassembly, clean the outside of the front and rear differential assembly and remove any sand and mud to prevent it from entering the assembly during disassembly and installation. 2. When removing connected parts made of a light alloy, such as front and rear differential carrier covers, tap them off with a plastic hammer. Do not attempt to pry them off with a screwdriver. 3. Always arrange disassembled parts in order and protect them from dust. 4. Before installation, thoroughly clean and dry each part and then apply hypoid gear oil LSD to it. Do not use alkaline cleaner for aluminum or rubber parts and ring gear set bolts. Also, do not clean rubber parts such as O-rings or oil seals with white gasoline. 5. Coat all sliding surfaces and rotating parts with hypoid gear oil LSD. 6. When holding components in a vice, be sure to place an aluminum sheet under the M part. Do not put them directly in the vice. 7. Be careful not to damage the contact surfaces of the case. Such damage could cause oil leakage. 8. Before applying sealant, remove any deposited oil sealant and clean the part to be sealed using white gasoline. 9. Do not supply oil immediately after installing sealed parts. Leave them for at least an hour. 10. Damage to the surfaces in direct contact with oil seals, O-rings or gaskets could cause oil leakage. Special attention should be paid. 11. When press-fitting an oil seal, be careful not to damage the oil seal lip and outside periphery. 12. When replacing a bearing, replace the inner and outer races as a set. PROBLEM SYMPTOMS TABLE HINT: Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in order. If necessary, replace these parts. DIFFERENTIAL SYSTEM PROBLEM SYMPTOMS CHART Symptom Suspected area 1. Oil level (Too high or wrong grade) Oil leakage from front differential 2. Front differential rear oil seal (Worn or damaged)

Go To DIFFERENTIAL OIL INSTALLATION

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

3. Companion flange (Loose or damaged) (1GR-FE) 4. Companion flange (Loose or damaged) (2UZ-FE) 1. Oil level (Too high or wrong grade) 2. Rear differential front oil seal Oil leakage from rear differential (worn or damaged) 3. Companion flange (Loose Or damaged) 1. Oil level (Too high or wrong grade) 2. Front differential rear oil seal Oil leak from front drive pinion (Worn or damaged) shaft 3. Companion flange (Loose or damaged) (1GR-FE) 4. Companion flange (Loose or damaged) (2UZ-FE) 1. Oil level (Too high or wrong grade) Oil leak from rear drive pinion 2. Rear differential front oil seal shaft (Worn or damaged) 3. Companion flange (Loose or damaged)

INSTALLATION INSTALLATION DIFFERENTIAL OIL REMOVAL INSPECTION DIFFERENTIAL OIL INSTALLATION INSTALLATION INSTALLATION DIFFERENTIAL OIL INSTALLATION INSTALLATION

DIFFERENTIAL OIL ADJUSTMENT 1. INSPECT DIFFERENTIAL OIL a. Stop the vehicle on a level place. b. Remove the differential filler plug and gasket. c. Check that the oil level is within 5mm (0 to 0.20 in.) of the bottom of the filler plug opening. NOTE:

 

Excessively large or small quantities of oil may cause problems. After replacing the oil, drive the vehicle and check the oil level again.

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Fig. 1: Identifying Differential Oil Level HINT: If necessary, fill the rear differential carrier assembly with hypoid gear oil. Oil grade: Hypoid gear oil API GL-5 Recommended viscosity: Above -18°C (0°F) SAE 90 Below -18°C (0°F) SAE 80W or 80W-90 Capacity: Front differential carrier assembly: 1.35 to 1.45 litters (1.43 to 1.53 US qts, 1.19 to 1.27 Imp. qts) Rear differential carrier assembly 3.00 to 3.10 litters (3.17 to 3.27 US qts, 2.64 to 2.72 Imp. qts) d. Check for oil leakage if the oil level is low. e. Install the differential filler plug and a new gasket. Torque: Front differential carrier assembly 39 N*m (398 kgf*cm, 29 ft.*lbf) Rear differential carrier assembly 49 N*m (500 kgf*cm, 36 ft.*lbf)

REAR DIFFERENTIAL CARRIER OIL SEAL Microsoft Wednesday, August 05, 2009 3:48:07 PM

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COMPONENTS

Fig. 2: Identifying Rear Differential Carrier Oil Seal Components With Torque Specifications REMOVAL 1. DRAIN DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) 2. REMOVE PROPELLER SHAFT ASSEMBLY Microsoft Wednesday, August 05, 2009 3:48:07 PM

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a. Place matchmarks on the propeller shaft flange and differential flange. b. 2WD Drive Type: Remove the 4 nuts and 4 washers. c. 4WD Drive Type: Remove the 4 nuts, 4 bolts and 4 washers. d. Suspend the propeller shaft assembly with wire or similar.

Fig. 3: Identifying Matchmarks On Propeller Shaft Flange 3. REMOVE REAR DRIVE PINION NUT a. Using SST and a hammer, unstake the nut. SST 09930-00010

Fig. 4: Unstaking Nut b. Using SST to hold the companion flange, remove the nut. SST 09330-00021

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

Fig. 5: Holding Companion Flange 4. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR a. Using SST, remove the companion flange. SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)

Fig. 6: Removing Companion Flange 5. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL a. Using SST, remove the oil seal. SST 09308-10010 6. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER

Fig. 7: Removing Oil Seal Microsoft Wednesday, August 05, 2009 3:48:07 PM

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

7. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING a. Using SST, remove the front bearing. SST 09556-22010 b. Using SST, remove the front bearing outer race. SST 09308-00010 c. Using a screwdriver, bend the oil storage ring and remove it. 8. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER

Fig. 8: Removing Front Bearing Outer Race INSTALLATION 1. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER a. Install a new rear differential drive pinion bearing spacer. 2. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING a. Using a brass bar and a hammer, install a new oil storage ring. b. Using SST and a hammer, install the front bearing outer race. c. Install the front bearing. SST 09316-60011 (09316-00011, 09316-00021) 3. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 4. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL a. Using SST and a hammer, install a new oil seal. SST 09554-30011 Oil seal drive in depth: 0.7 to 1.3 mm (0.0276 to 0.0512 in.) b. Coat oil seal lip with MP grease. Microsoft Wednesday, August 05, 2009 3:48:08 PM

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Fig. 9: Installing Oil Seal 5. INSTALL REAR DRIVE COMPANION FLANGE SUB-ASSEMBLY REAR a. Using SST, install the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030) b. Coat the threads of a new nut with hypoid gear oil LSD.

Fig. 10: Installing Companion Flange c. Using SST to hold the companion flange, tighten the nut. SST 09330-00021 (09330-00030) Torque: 215 N*m (2,190 kgf*cm, 159 ft.*lbf)

Fig. 11: Holding Companion Flange Microsoft Wednesday, August 05, 2009 3:48:08 PM

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6. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD a. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring rear. New bearing: 1.05 to 1.64 N*m (10.7 to 16.7 kgf*cm, 9.3 to 14.5 in.*lbf) Reused bearing: 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.

Fig. 12: Measuring Preload Of Backlash Between Drive Pinion And Ring Rear 7. INSTALL REAR DRIVE PINION NUT a. Using a chisel and a hammer, stake the nut.

Fig. 13: Staking Nut 8. INSTALL PROPELLER SHAFT ASSEMBLY a. Align the matchmarks on the propeller shaft differential flange. b. 2WD Drive Type: Install the propeller shaft with the 4 washers and 4 nuts. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) c. 4WD Drive Type: Install the propeller shaft with the 4 bolts, 4 washers and 4 nuts. Microsoft Wednesday, August 05, 2009 3:48:08 PM

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Fig. 14: Identifying Matchmarks On Propeller Shaft Flange Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) 9. FILL UP DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) 10. INSPECT DIFFERENTIAL OIL (See DIFFERENTIAL OIL )

DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (FOR 4WD) COMPONENTS

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Fig. 15: Identifying Differential Side Gear Shaft Oil Seal Components (For 4WD) REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE ENGINE UNDER COVER ASSEMBLY REAR a. Remove the 6 bolts and engine under cover assembly rear. 3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY a. Remove the 4 bolts and No. 1 engine under cover sub-assembly. 4. DRAIN DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) 5. REMOVE FRONT AXLE HUB LH NUT (See REMOVAL ) 6. SEPARATE FRONT SPEED SENSOR LH (See REMOVAL ) Microsoft Wednesday, August 05, 2009 3:48:08 PM

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7. SEPARATE TIE ROD END SUB-ASSEMBLY LH (See REMOVAL ) 8. SEPARATE NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH (See REMOVAL ) 9. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See REMOVAL ) 10. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL a. Using SST, remove the oil seal. SST 09308-00010

Fig. 16: Removing Oil Seal INSTALLATION 1. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL a. Using SST and a hammer, install a new oil seal. SST 09554-30011 b. Coat the oil seal lip with MP grease. 2. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See INSTALLATION ) 3. CONNECT NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH (See INSTALLATION )

Fig. 17: Installing Oil Seal Microsoft Wednesday, August 05, 2009 3:48:08 PM

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4. 5. 6. 7. 8. 9.

CONNECT TIE ROD END SUB-ASSEMBLY LH (See INSTALLATION ) CONNECT FRONT SPEED SENSOR LH (See INSTALLATION ) INSTALL FRONT AXLE HUB LH NUT (See INSTALLATION ) FILL UP DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) INSPECT DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY a. Install the No. 1 engine under cover sub-assembly with the 4 bolts. 10. INSTALL ENGINE UNDER COVER ASSEMBLY REAR a. Install the engine under cover assembly with the 6 bolts. 11. INSTALL FRONT WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) 12. INSPECT ABS SPEED SENSOR SIGNAL HINT: (See TEST MODE PROCEDURE )

1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (FOR 4WD) COMPONENTS

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Fig. 18: Identifying 1GR-FE Front Differential Carrier Assembly Components With Torque Specifications - For 4WD (1 Of 3)

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Fig. 19: Identifying 1GR-FE Front Differential Carrier Assembly Components With Torque Specifications - For 4WD (2 Of 3)

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Fig. 20: Identifying 1GR-FE Front Differential Carrier Assembly Components With Torque Specifications - For 4WD (3 Of 3) REMOVAL 1. REMOVE FRONT WHEELS 2. REMOVE REAR ENGINE UNDER COVER ASSEMBLY a. Remove the 6 bolts and engine under cover assembly. Microsoft Wednesday, August 05, 2009 3:48:08 PM

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY a. Remove the 4 bolts and No. 1 engine under cover sub-assembly. 4. DRAIN DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) 5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (See REMOVAL ) 6. REMOVE FRONT AXLE HUB LH NUT (See REMOVAL ) 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 ) 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 ) 11. SEPARATE FRONT SPEED SENSOR RH HINT: Use the same procedure as for the LH side. 12. 13. 14. 15.

SEPARATE TIE ROD END SUB-ASSEMBLY LH (See REMOVAL ) SEPARATE TIE ROD END SUB-ASSEMBLY RH (See REMOVAL ) REMOVE NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH (See REMOVAL ) 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 ) 17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See REMOVAL ) 18. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY a. Remove the bolt and separate the front differential breather tube bracket. b. Support the front differential with a jack. c. Remove the front differential mount nut No. 1. d. Remove the 2 front mounting bolts and 2 nuts. e. Disconnect the actuator hose and connector. Microsoft Wednesday, August 05, 2009 3:48:08 PM

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

f. Lower the jack and remove the front differential assembly. g. Remove the 2 bolts and No. 3 front differential support. h. Remove the 5 bolts and 2 front differential supports.

Fig. 21: Locating Front Differential Carrier Assembly Bolts DISASSEMBLY 1. REMOVE DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY a. Remove the 4 bolts. b. Using a hammer, handle, remove the actuator assembly.

Fig. 22: Removing Actuator Assembly 2. REMOVE FRONT DIFFERENTIAL TUBE ASSEMBLY a. Remove the 4 bolts. b. Using a plastic hammer, remove the differential tube.

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Fig. 23: Removing Differential Tube 3. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL a. Using SST, remove the oil seal. SST 09308-00010

Fig. 24: Removing Oil Seal 4. REMOVE DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY a. Using SST, remove the side gear inter shaft. SST 09350-20015 (09369-20040), 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-04011) b. Remove the snap ring from the side gear inter shaft.

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Fig. 25: Removing Side Gear Inter Shaft 5. REMOVE FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY a. Using SST and a hammer, remove the nut. SST 09930-00010

Fig. 26: Removing Nut b. Using SST to hold the companion flange, remove the nut. SST 09330-00021 (09330-00030)

Fig. 27: Holding Companion Flange c. Using SST, remove the companion flange. SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

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Fig. 28: Removing Companion Flange 6. REMOVE FRONT DIFFERENTIAL CARRIER OIL SEAL a. Using SST, remove the oil seal from the differential carrier assembly. SST 09308-10010 7. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

Fig. 29: Removing Oil Seal From Differential Carrier Assembly 8. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING a. Using SST, remove the rear bearing from the drive pinion. SST 09556-22010 b. Remove the bearing spacer. 9. REMOVE DIFFERENTIAL SIDE BEARING RETAINER a. Using a screwdriver, remove the union. b. Remove the 10 bolts and tap out the side bearing retainer with a plastic hammer.

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Fig. 30: Removing Union 10. REMOVE DIFFERENTIAL CASE ASSEMBLY 11. REMOVE DIFFERENTIAL DRIVE PINION 12. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING a. 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.

Fig. 31: Removing Front Bearing And Washer From Drive Pinion 13. REMOVE FRONT BEARING OUTER RACE a. Using a brass bar and a hammer, remove the front bearing outer race.

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Fig. 32: Removing Front Bearing Outer Race 14. REMOVE REAR BEARING OUTER RACE a. Using SST, remove the rear bearing outer race. SST 09502-12010, 09612-65014 (09612-01020, 09612-01050) b. Using a brass bar and a hammer, remove the oil storage ring. 15. 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.

Fig. 33: Removing Rear Bearing Outer Race a. 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)

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

Fig. 34: Removing Outer Race And Plate Washer From Bearing Retainer b. 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) 16. REMOVE DIFFERENTIAL RING GEAR a. Place matchmarks on the ring gear and differential case assembly. b. Remove the 10 bolts. c. Using a plastic hammer, tap on the ring gear to separate it from the differential case assembly.

Fig. 35: Identifying Matchmarks On Ring Gear And Differential Case Assembly 17. REMOVE FRONT DIFFERENTIAL CASE BEARING a. 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.

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

Fig. 36: Removing Differential Case Bearings From Differential Case Assembly 18. DISASSEMBLE DIFFERENTIAL CASE a. Using a pin punch and a hammer, remove the straight pin. b. Remove these parts from the differential case assembly. 1. 2 Differential side gears 2. 2 Differential side gear thrust washers 3. Differential pinion shaft 4. 2 Differential pinion gears 5. 2 Differential pinion gear thrust washers

Fig. 37: Removing Straight Pin 19. INSPECT DIFFERENTIAL GEAR KIT a. 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. 20. INSPECT FRONT DIFFERENTIAL CASE a. Check that the differential case assembly is not damaged. If the differential case assembly is damaged, replace it. 21. REMOVE FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING Microsoft Wednesday, August 05, 2009 3:48:08 PM

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

a. Using a brass bar and hammer, remove the 2 bearings.

Fig. 38: Removing Bearings 22. REMOVE DIFFERENTIAL CLUTCH HUB a. Using a snap ring expander, remove the snap ring. b. Remove the differential clutch hub.

Fig. 39: Removing Snap Ring 23. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL a. Using SST, remove the oil seal from the differential tube. SST 09308-00010

Fig. 40: Removing Oil Seal From Differential Tube Microsoft Wednesday, August 05, 2009 3:48:08 PM

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24. REMOVE DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH a. Using a snap ring expander, remove the snap ring. b. Remove the side gear shaft from the differential tube.

Fig. 41: Removing/Installing Snap Ring 25. REMOVE FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING a. Using a snap ring expander, remove the snap ring. b. Using SST, a brass bar and a press, remove the bearing. SST 09950-00020 NOTE:

Do not damage the bearing.

Fig. 42: Removing Bearing And Snap Ring 26. REMOVE FRONT DIFFERENTIAL DUST DEFLECTOR a. Using SST, a socket wrench and a press, remove the dust deflector. SST 09950-00020

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Fig. 43: Removing Dust Deflector 27. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL CLUTCH HUB a. Check for wear and damage to the clutch hub and clutch sleeve. If necessary, replace them. b. Check that the clutch sleeve slides smoothly on the clutch hub.

Fig. 44: Checking Wear And Damage Of Clutch Hub And Clutch Sleeve 28. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND DIFFERENTIAL SIDE GEAR INTER SHAFT a. Check for wear and damage to the clutch hub and side gear inter shaft. b. Check that the clutch sleeve slides smoothly on the side gear inter shaft.

Fig. 45: Checking Wear And Damage Of Clutch Hub And Side Gear Inter Shaft Microsoft Wednesday, August 05, 2009 3:48:08 PM

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29. INSPECT DIFFERENTIAL CLUTCH SLEEVE AND CLUTCH SLEEVE FORK CLEARANCE a. Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve. Maximum clearance: 0.35 mm (0.0138 in.) If the clearance exceeds the maximum, replace the fork or clutch sleeve.

Fig. 46: Measuring Clearance Between Sleeve Fork And Clutch Sleeve INSPECTION 1. INSPECT BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION a. Using SST and a dial indicator, measure the ring gear backlash. SST 09564-32011 Backlash: 0.11 to 0.18 mm (0.0043 to 0.0071 in.) If the backlash is not within the specification, adjust or repair the side bearing preload as necessary.

Fig. 47: Measuring Ring Gear Backlash 2. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD a. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Torque: 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) Microsoft Wednesday, August 05, 2009 3:48:08 PM

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If necessary, disassemble and inspect the differential assembly. 3. INSPECT TOTAL PRELOAD a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.20 to 0.63 N*m (2.0 to 6.4 kgf*cm, 1.8 to 5.6 in.*lbf) If necessary, disassemble and inspect the differential.

Fig. 48: Measuring Preload With Teeth Of Drive Pinion And Ring Gear In Contact REASSEMBLY 1. INSTALL FRONT DIFFERENTIAL DUST DEFLECTOR a. Using a steel plate and a press, install a new dust deflector. NOTE:

Do not damage the dust deflector.

Fig. 49: Installing Dust Deflector 2. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING a. Using SST and a press, install the bearing. SST 09223-00010 Microsoft Wednesday, August 05, 2009 3:48:08 PM

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b. Using a snap ring expander, install the snap ring.

Fig. 50: Removing/Installing Snap Ring 3. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY RH a. Install the side gear shaft into the differential tube. b. Using snap ring pliers, install the snap ring.

Fig. 51: Removing/Installing Snap Ring 4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL a. Using SST and a plastic hammer, install a new oil seal. SST 09608-32010 Oil seal drive in depth: 4.8 to 5.8 mm (0.1890 to 0.2284 in.) b. Coat the oil seal lip with MP grease.

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Fig. 52: Installing Oil Seal 5. INSTALL DIFFERENTIAL CLUTCH HUB a. Install the clutch hub onto the side gear inter shaft. b. Using snap ring pliers, install the snap ring. NOTE:

Be sure to install the differential clutch hub in the correct direction.

Fig. 53: Installing Clutch Hub Onto Side Gear Inter Shaft 6. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING a. Using SST and a press, install 2 new bearings. SST 09950-60010 (09951-00380) Bearing press in depth: 1.4 to 2.0 mm (0.055 to 0.079 in.)

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

Fig. 54: Installing Bearings 7. INSTALL FRONT DIFFERENTIAL CASE a. Install the 2 proper thrust washers onto the 2 side gears. HINT: Using the table below, select the thrust washer which will ensure that the backlash is within the specifications. Washer thickness WASHER THICKNESS SPECIFICATION Thickness mm (in.) Thickness mm (in.) 1.48 to 1.52 (0.0583 to 0.0598) 1.73 to 1.77 (0.0681 to 0.0697) 1.53 to 1.57 (0.0602 to 0.0618) 1.78 to 1.82 (0.0701 to 0.0717) 1.58 to 1.62 (0.0622 to 0.0638) 1.83 to 1.87 (0.0720 to 0.0736) 1.63 to 1.67 (0.0642 to 0.0657) 1.88 to 1.92 (0.0740 to 0.0756) 1.68 to 1.72 (0.0661 to 0.0677) -

Fig. 55: Installing Thrust Washer b. Install the 2 side gears, 2 side gear thrust washers, 2 pinion gears, 2 pinion gear thrust washers and pinion shaft into the differential case assembly. HINT: Align the holes of the differential case assembly and pinion shaft. c. Measure the side gear backlash. 1. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case assembly. Backlash: 0 to 0.15 mm (0 to 0.0059 in.) Microsoft Wednesday, August 05, 2009 3:48:08 PM

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

If the backlash is not within the specification, install a side gear thrust washer with a different thickness.

Fig. 56: Measuring Side Gear Backlash d. Using a pin punch and hammer, install the straight pin through the differential case assembly and hole of the pinion shaft. e. Stake the differential case assembly.

Fig. 57: Installing Straight Pin 8. INSTALL DIFFERENTIAL RING GEAR a. Clean the contact surfaces of the differential case assembly and ring gear. b. Heat the ring gear to about 100°C (212°F) in boiling water. c. Carefully take the ring gear out of the boiling water. d. After any moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case assembly. HINT: Align the matchmarks on the ring gear and differential case assembly. e. Temporarily install 10 bolts so that the bolt holes in the ring gear and differential case assembly are aligned. Microsoft Wednesday, August 05, 2009 3:48:08 PM

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

Fig. 58: Cleaning Contact Surfaces Of Differential Case f. After the ring gear has cooled sufficiently, tighten the ring gear set bolts to which thread lock has been applied. Torque: 97 N*m (985 kgf*cm, 71 ft.*lbf) Thread lock: Part No. 08833-00100, THREE BOND 1360k or equivalent 9. INSTALL FRONT DIFFERENTIAL CASE BEARING a. Using SST and a press, install the 2 differential case bearings into the differential case assembly. SST 09226-10010 10. INSTALL SIDE BEARING OUTER RACE HINT: When replacing the 2 differential case bearings, fit 2 of the thinnest new washers to each bearing and when reusing the bearings, fit washers of the same thickness as those removed.

Fig. 59: Installing Side Bearing Outer Race a. Install a new plate washer to the side bearing retainer. b. Using SST and a press, install the bearing outer race onto the differential case bearing retainer assembly. Microsoft Wednesday, August 05, 2009 3:48:08 PM

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

SST 09950-60020 (09951 -00810), 09950-70010 (09951-07150) c. Install a new plate washer onto the differential carrier assembly.

Fig. 60: Installing Bearing Outer Race Onto Differential Case Bearing Retainer Assembly d. Using SST and a press, install the bearing outer race onto the differential carrier assembly. SST 09950-60020 (09951 -00810), 09950-70010 (09951-07150)

Fig. 61: Installing Bearing Outer Race Onto Differential Carrier Assembly 11. INSTALL FRONT BEARING OUTER RACE a. Using SST, install the outer race. SST 09950-00020 (09951 -00680, 09951 -00890) 12. INSTALL REAR BEARING OUTER RACE a. Install the oil storage ring. b. Using SST, install the outer race. SST 09950-00020 (09951 -00680, 09951 -00890) 13. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING a. Install the washer onto the drive pinion. HINT: Microsoft Wednesday, August 05, 2009 3:48:08 PM

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

First, fit a washer of the same thickness as the removed washer, then after checking the tooth contact pattern, replace the washer with one of a differential thickness if necessary.

Fig. 62: Installing Outer Race b. Using SST and a press, install the front bearing onto the drive pinion. SST 09506-30012 14. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD a. Install the drive pinion. HINT: Assemble the spacer and oil seal after adjusting the ring gear tooth contact pattern.

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

Fig. 63: Installing Front Bearing Onto Drive Pinion b. Using SST, install the rear bearing, oil slinger and companion flange. SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) c. Coat the threads of the nut with hypoid gear oil.

Fig. 64: Installing Rear Bearing, Oil Slinger And Companion Flange d. Adjust the drive pinion preload by tightening the companion flange nut. e. Using SST to hold the companion flange, tighten the nut. SST 09330-00021 (09330-00030) NOTE:

As there is no spacer, tighten the nut a little at a time, being careful not to overtighten it.

Fig. 65: Holding Companion Flange f. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting) BEARING SPECIFICATION Bearing Standard Microsoft Wednesday, August 05, 2009 3:48:08 PM

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

New 0.98 to 1.57 N*m (10 to 16 kgf*cm, 8.7 to 13.9 in.*lbf) Reused 0.49 to 0.78 N*m (5 to 8 kgf*cm, 4.3 to 6.9 in.*lbf) If necessary, disassemble and inspect the differential assembly.

Fig. 66: Measuring Preload Of Backlash Between Drive Pinion And Ring Gear 15. INSTALL DIFFERENTIAL CASE ASSEMBLY 16. ADJUST BACKLASH DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION a. Install the side bearing retainer with the 10 bolts. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) b. Using SST and a dial indicator, measure the ring gear backlash. SST 09564-32011 Backlash: 0.11 to 0.18 mm (0.0043 to 0.0071 in.) c. If it is not within the specification, adjust it by either increasing or decreasing the thickness of the washers on both sides by an equal amount. HINT: There should be no clearance between the plate washer and differential case. Make sure that there is ring gear backlash.

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2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner

Fig. 67: Measuring Ring Gear Backlash Washer thickness WASHER THICKNESS SPECIFICATION Thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 1.59 to 1.61 (0.0626 to 0.0634) 1.89 to 1.91 (0.0744 to 0.0752) 2.19 to 2.21 (0.0862 to 0.0870) 1.62 to 1.64 (0.0638 to 0.0646) 1.92 to 1.94 (0.0756 to 0.0764) 2.22 to 2.24 (0.0874 to 0.0882) 1.65 to 1.67 (0.0650 to 0.0657) 1.95 to 1.97 (0.0768 to 0.0776) 2.25 to 2.27 (0.0886 to 0.0894) 1.68 to 1.70 (0.0661 to 0.0669) 1.98 to 2.00 (0.0780 to 0.0787) 2.28 to 2.30 (0.0898 to 0.0906) 1.71 to 1.73 (0.0673 to 0.0681) 2.01 to 2.03 (0.0791 to 0.0800) 2.31 to 2.33 (0.0909 to 0.0917) 1.74 to 1.76 (0.0685 to 0.0693) 2.04 to 2.06 (0.0803 to 0.0811) 2.34 to 2.36 (0.0921 to 0.0929) 1.77 to 1.79 (0.0697 to 0.0705) 2.07 to 2.09 (0.0815 to 0.0823) 2.37 to 2.39 (0.0933 to 0.0941) 1.80 to 1.82 (0.0709 to 0.0717) 2.10 to 2.12 (0.0827 to 0.0835) 2.40 to 2.42 (0.0945 to 0.0953) 1.83 to 1.85 (0.0720 to 0.0728) 2.13 to 2.15 (0.0839 to 0.0846) 2.43 to 2.45 (0.0957 to 0.0965) 1.86 to 1.88 (0.0732 to 0.0740) 2.16 to 2.18 (0.0850 to 0.0858) 2.46 to 2.48 (0.0969 to 0.0976) 17. INSPECT TOTAL PRELOAD a. Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact. Total preload (at starting): Drive pinion preload plus 0.20 to 0.63 N*m (2.0 to 6.4 kgf*cm, 1.8 to 5.6 in.*lbf) If necessary, disassemble and inspect the differential.

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