Disassembly

1. CHECK COMPANION FLANGE RUNOUT

Using a dial indicator, measure the vertical and lateral runout of the companion flange. Maximum runout: 0.10 mm (0.0039 in.)

If the runout exceeds the maximum, replace the companion flange.

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

Bearing Lateral Runout

G02927630

Fig. 4: Measuring Companion Flange Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. CHECK RING GEAR BACKLASH

Using SST and a dial indicator, measure the ring gear backlash. SST 09564-3201 1

Backlash: 0.1 - 0.18 mm (0.0039 - 0.0071 in.) NOTE: Measure at 3 or more points on the circumference of the ring gear.

If the backlash is not within the specified value, adjust the side bearing preload or repair as necessary.

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

G02927631

Fig. 5: Measuring Ring Gear Backlash

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

3. MEASURE DRIVE PINION PRELOAD

Using a torque wrench, measure the preload using the backlash between the drive pinion and ring gear. Preload (at starting):

4. CHECK 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 0.4 - 0.6 N.m (4 - 6 kgf.cm, 3.5 - 5.2 in..lbf)

If necessary, disassemble and inspect the differential.

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

G02927632

Fig. 6: Measuring Total Preload

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

5. REMOVE A.D.D. ACTUATOR

a. Remove the 4 bolts.

b. Using a hammer handle, remove the actuator.

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

Sequoia Differential Actuator

G02927633

Fig. 7: Removing A.D.D Actuator

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

6. REMOVE DIFFERENTIAL TUBE

a. Using a Torx socket (E14), remove the 4 Torx bolts.

b. Using a plastic hammer, tap on the differential tube to remove it.

c. Remove the sleeve.

d. Remove the O-ring from the differential tube.

7. REMOVE CLUTCH CASE

a. Using a Torx socket (E14), remove the 2 Torx bolts.

b. Using a plastic hammer, tap on the clutch case to remove it.

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

G02927634

Fig. 8: Removing Differential Tube

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

8. REMOVE SIDE OIL SEAL

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

Using SST, remove the side oil seal. SST 09308-00010

G02927635

Fig. 9: Removing Side Oil Seal

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

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

G02927636

Fig. 10: Removing Intermediate Shaft No. 1 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

9. REMOVE INTERMEDIATE SHAFT NO. 1

a. Using SST, remove the intermediate shaft No. 1.

SST 09350-20015 (09369-20040), 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04011, 09957-04010, 09958-0401 1)

b. Remove the snap ring.

10. REMOVE COMPANION FLANGE

a. Using a chisel and hammer, unstake the nut.

b. Using SST to hold the flange, remove the nut.

SST 09330-00021

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

G02927637

Fig. 11: Using SST To Hold Flange & Removing Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Using SST, remove the companion flange.

SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020)

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

Fig. 12: Removing Companion Flange

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

Fig. 12: Removing Companion Flange

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

11. REMOVE OIL SEAL AND OIL SLINGER

a. Using SST, remove the oil seal.

SST 09308-10010

b. Remove the oil slinger.

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

G02927639

Fig. 13: Removing Oil Seal & Oil Slinger Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

12. REMOVE REAR BEARING AND BEARING SPACER

a. Using SST, remove the rear bearing from the drive pinion.

SST 09556-22010

b. Remove the bearing spacer.

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

Sst 09308 10010

G02927640

Fig. 14: Removing Bearing Spacer

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

13. REMOVE SIDE BEARING RETAINER

Remove the 10 bolts and tap out the retainer with a plastic hammer.

14. REMOVE DIFFERENTIAL CASE ASSEMBLY

15. REMOVE DRIVE PINION FROM DIFFERENTIAL CARRIER

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

Fig. 15: Removing Side Bearing Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

16. REMOVE DRIVE PINION FRONT BEARING

Using SST and a press, remove the bearing and washer from the drive pinion. SST 09950-00020

NOTE:

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

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

G02927642

Fig. 16: Removing Drive Pinion Front Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

17. REMOVE DRIVE PINION BEARING OUTER RACES

a. Using a brass bar and hammer, remove the front bearing outer race.

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

Fig. 17: Removing Drive Pinion Bearing Outer Races Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Using SST, remove the rear bearing outer race.

SST 09502-12010, 09612-65014 (09612-01020, 09612-01050) 18. REMOVE SIDE BEARING OUTER RACES

NOTE:

• Measure the plate washer thickness and note it down.

• Tag the bearing outer races to show the location for reassembling.

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

G02927644

Fig. 18: Measuring Plate Washer Thickness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

a. Using SST and a press, remove the plate washer and outer race from the bearing retainer. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150)

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

G02927645

Fig. 19: Removing Plate Washer & Outer Race From Bearing Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

b. Using SST and a press, remove the plate washer and outer race from the differential carrier. SST 09950-60010 (09951-00650), 09950-70010 (09951-07150)

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

Fig. 20: Removing Plate Washer & Outer Race From Differential Carrier Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

19. REMOVE RING GEAR

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

b. Using a screwdriver and hammer, unstake the 5 lock plates.

c. Remove the 10 bolts and 5 lock plates.

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

2004 DRIVELINE/AXLES Front Differential Carrier - Sequoia

VJ
Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

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Responses

  • AMINA
    How to change sequoia front bearing?
    8 years ago
  • liisa
    How to replace intermediate shaft on 2004 camry?
    8 years ago
  • yvonne finkel
    How to remove the FRONT differential 2004 TOYOTA SIENNA?
    7 years ago

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