Differential Assembly Tacoma Runner

Disassembly (With Electronic Locking Differential)

1. Using dial indicator, check vertical and lateral runout of drive pinion companion flange. See Fig. 6 . Replace companion flange if vertical or lateral runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS .

2. Using dial indicator, check ring gear runout on backside of ring gear while rotating pinion flange. See Fig. 7 . Replace ring gear and drive pinion as a set if ring gear runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS .

3. Using a dial indicator, check ring gear backlash while holding drive pinion from rotating. See Fig. 7 . Ring gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS . If ring gear backlash is not within specification, adjust side bearing preload or repair as necessary.

4. Using an INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque required to start rotation of drive pinion to determine drive pinion bearing preload for reassembly reference. Drive pinion rotating torque should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

5. Using an INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to rotate drive pinion and ring gear for reassembly reference. Total assembled preload should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .

6. Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION.

7. Remove electronic locking differential actuator from differential carrier. Remove and discard "O" ring. Remove electronic locking differential indicator switch and gasket. Remove electronic locking differential screw plugs, spring seat, compression spring and ball. See Fig. 9 .

8. Using a pin punch and hammer, remove slotted spring pin. Remove bolts from shaft retainer. Using a plastic hammer, remove shaft retainer. Using a screwdriver, remove shift fork shaft.

9. Using hammer and chisel, loosen staked area on drive pinion lock nut. Remove drive pinion nut.

10. Using a puller, remove companion flange from drive pinion. Remove oil seal from differential carrier.

11. Note direction of oil slinger installation and remove oil slinger (if equipped). Using a puller, remove front bearing from drive pinion.

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

12. Place reference marks on side bearing caps and differential carrier for reassembly reference. Mark adjusting nut and side bearing race location for reassembly reference. Components must be installed in original location.

13. Remove adjusting nut locks located on each side bearing cap. Remove bolts and remove side bearing caps. Remove differential case with side bearing outer races, adjusting nuts and sleeve. Remove shift fork.

14. Remove drive pinion from differential carrier. Remove bearing spacer. Press rear bearing from drive pinion (if necessary). Remove washer from drive pinion. If drive pinion or ring gear are damaged, replace them as a set. Using puller, remove front bearing race from differential carrier (if necessary).

15. Using a hammer and brass drift, remove oil storage ring from differential carrier (if necessary). Using a hammer and brass drift, remove rear bearing race from differential carrier (if necessary).

16. Place reference mark on ring gear and differential case for reassembly reference. Bend over tabs on lock plates on ring gear bolts. Remove ring gear bolts. Using soft-face hammer, tap ring gear from differential case.

17. Reinstall differential case with side bearings and races in differential case. Install side bearing caps and adjusting nuts. Tighten adjusting nuts until no play exists in side bearing. Tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS .

18. Using dial indicator, check differential case runout at ring gear mounting surface on differential case while rotating differential case. Replace differential case if runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS . Remove differential case and components from differential carrier.

19. Using puller, remove side bearings from differential case (if necessary). Place reference marks on differential cases for reassembly reference. See Fig. 9 . Remove differential case bolts uniformly, in small increments.

20. Using soft-face hammer, separate differential cases. Remove pinion gears, side gears, thrust washers and spider.

21. Install sleeve in left differential case and check that sleeve moves smoothly. Using feeler gauge, measure clearance between shift fork and sleeve. See Fig. 10 . Clearance should be .006-.014" (0.15-0.36 mm). Using press, remove dust deflector from companion flange (if necessary).

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

Rear Axle Assembly For Toyota Sequoia
Fig. 6: Checking Companion Flange Vertical & Lateral Runout (Typical) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

Differential Carrier Runout
CHECKING RING GEAR BACKLASH
Differential Backlash Gauge

CHECKING SIDE GEAR BACKLASH

G94J47836

CHECKING SIDE GEAR BACKLASH

G94J47836

Fig. 7: Checking Ring Gear Runout, Ring Gear Backlash & Side Gear Backlash (Typical) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

Differensial Case Motor
Fig. 8: Checking Side Gear Backlash On 4 Pinion Type Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A, INC.

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

1997 4runner Rear Axle Assembly

Fig. 9: Exploded View Of Differential Assembly (Tacoma & 4Runner With Electronic Locking Differential)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 9: Exploded View Of Differential Assembly (Tacoma & 4Runner With Electronic Locking Differential)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001 DRIVE AXLES Differentials & Axle Shafts - Rear Separate Carrier

Differential Carrier Gasket Replacement

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Responses

  • Brunilde Bianchi
    How to change differential carrier gasket 4runner 94?
    8 years ago
  • Torsten
    How to set up a 2001 toyota tacoma differential?
    8 years ago
  • ULRICH
    How to remove hilux rear axle?
    8 years ago
  • Gruffo
    How to put a rear brake assembly on for a 1996 toyota tercel?
    7 years ago
  • Devin
    How to install a differential in a 1996 toyota tercel?
    7 years ago
  • atso
    How to check ring gear runout?
    7 years ago
  • semira
    How to check differential backlash?
    7 years ago
  • frank
    How to check deferential case runout?
    5 years ago
  • veera
    How to replace pinion bearing in a 1997 toyota 4 runner?
    2 years ago

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