Remover

Toyota Rav4 Rear Differential Assembly

G00029052

Fig. 2: Separating Axle Shafts From Differential Assembly Courtesy of TOYOTA MOTOR SALES U.S.A., LTD.

INSPECTION

2002-04 AXLE SHAFTS Axle Shafts - Front - Sequoia

Ensure no play exists in outboard joint. Inboard joint must slide smoothly in thrust direction and be free from excessive play in radial direction. Check for torn or damaged boots.

DISASSEMBLY

1. Pinch large inboard joint boot clamp and remove CV joint boot clamp.

2. Cut and remove small inboard CV joint boot clamp and 2 outboard CV joint boot clamps.

3. Paint alignment marks on CV joint housing and shaft for reassembly reference.

4. Expand snap ring at end of outboard joint and pull out outboard joint shaft while expanding snap ring.

5. Remove inboard and outboard CV joint boots. See Fig. 1 .

7. Using press, remove dust cover.

Shaft Axial Bearing And Retainer Ring
Fig. 3: Removing Axle Shaft Dust Cover

2004 Toyota Sequoia Limited

2002-04 AXLE SHAFTS Axle Shafts - Front - Sequoia

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

1. Using screwdriver and hammer, install NEW dust cover.

2. Using screwdriver and hammer, install NEW dust seal.

3. Wrap splines on axle shaft with tape to prevent damaging boots during installation.

4. Install NEW boots and NEW boot clamps on axle shaft. See Fig. 1 .

5. Install inboard joint to outboard joint, while expanding snap ring. Ensure alignment marks align.

6. Apply specified grease as to CV joints and boots. See GREASE CAPACITY SPECIFICATIONS .

7. Assemble boots onto CV joints.

8. Set axle shaft to standard length. See AXLE SHAFT LENGTH SPECIFICATIONS table. See Fig. 4 .

9. Install large inboard joint boot clamp to inboard joint boot using pliers to compress clamp.

10. Install and tighten remaining boot clamps. Tighten clamps so that the clamps pinch. See Fig. 5 . Clearance between clamps should be .039-.059" (1.0-1.5 mm).

G96J01301

Fig. 4: Measuring Axle Shaft Length

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

2002-04 AXLE SHAFTS Axle Shafts - Front - Sequoia

Axle Snap Ring

G00299413

Fig. 5: Install CV Joint Boot Clamps

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

INSTALLATION

1. Install NEW snap ring to inboard joint shaft. Set snap ring with opening side facing downward on axle shaft.

2. Coat appropriate gear oil to inboard joint shaft and differential case sliding surface.

3. Using brass drift and hammer, install axle shaft.

4. When axle shaft is installed, check that there is .08-12" (2-3 mm) of play in axial direction. Check that axle shaft can not be removed by hand.

5. Install upper side of shock absorber to chassis frame with 3 nuts. Tighten to specification. See TORQUE SPECIFICATIONS .

6. Connect lower side of shock absorber to lower suspension arm with bolt, washer and nut. Tighten to specification. See Fig. 1 .

7. Install lower ball joint to lower suspension arm. Install nut and NEW cotter pin. Face the hole of the cotter pin in forward direction.

8. While applying brakes, install axle shaft lock nut. Tighten to specification. Install lock cap and NEW cotter pin.

2002-04 AXLE SHAFTS Axle Shafts - Front - Sequoia

9. Fill differential with appropriate oil. Check for proper fluid level.

10. Install lower engine cover.

11. Install front wheels.

GREASE CAPACITY SPECIFICATIONS

GREASE CAPACITY SPECIFICATIONS

Application & Type

Oz. (g)

Outboard (Black)

7.23-7.94 (202-225)

Inboard (Black)

6.70-7.41 (190-210)

AXLE SHAFT LENGTH SPECIFICATIONS

AXLE SHAFT LENGTH SPECIFICATIONS

Application

(1) Length - In. (mm)

Sequoia

20.53-21.40 (521.5-525.5)

(l) Measured between axle shaft inboard joint flange and outboard joint flange. See Fig. 4 .

TORQUE SPECIFICATIONS

Application

Ft. Lbs. (N.m)

Axle Shaft Lock Nut

173 (235)

Lower Ball Joint Nut

103 (140)

Shock Absorber Bolt/Washer/Nut

100 (135)

Shock Absorber Upper Nuts

47 (64)

Wheel Lug Nuts

83 (110)

2004 BRAKES Troubleshooting - Sequoia

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.

Symptom

Suspect Area

1 ow pedal or spongy pedal

1 Fluid leaks for brake system

2. Air in brake system

3. Piston seals (Worn or damaged)

4 Master cylinder (Faulty)

1. 8rake pedal free play (Minimum)

2. Parking brake pedal travel (Out of adjustment)

3. Parking brake wire (Sticking)

4. Parking brake (Shoe clearance out of adjustment)

5. Pad (Cracked or distorted)

7. Piston (Frozen)

8. Tension or return spring (Faulty)

9. Vacuum leaks for booster system

10. Master cylinder (Faulty)

1. Piston (Stuck)

2. Pad (Cracked or distorted)

5. Vacuum leaks for booster system

6. Master cylinder (Faulty)

G02927790

G02927790

Fig. 1: Problem Symptoms Table (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2004 BRAKES Troubleshooting - Sequoia

1. Fluid leaks for brake system

2 Air in brake system

3. Pad (Worn)

4. Pad (Cracked or distorted)

Hard pedal but brake inefficient

8. Vacuum leaks for booster system

1. Pad (Cracked or distorted)

2. installation bolt (Loose)

3. Disc (Scored)

4. Pad support plate (Loose)

Noise from brakes

b. Sliding pin (Worn)

8 Tension or return spring (Faulty) 9. Anti-squeal shim (Damaged)

10.Shoe tiold-dowri spring (Damaged)

G02927799

G02927799

Fig. 2: Problem Symptoms Table (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 BRAKES Disc - Sequoia

2002-04 BRAKES Disc - Sequoia

DESCRIPTION & OPERATION

WARNING: For warnings and procedures regarding vehicles equipped with Anti-Lock Brake Systems (ABS), see appropriate ANTI-LOCK article.

Hydraulically operated disc brakes are used on front and rear of vehicle, along with a mechanically operated parking brake. The shoe-and-drum parking brake system operates inside rear brake rotors.

For ABS related information, see appropriate ABS article.

BLEEDING BRAKE SYSTEM

CAUTION: Do not let brake fluid remain on painted surfaces. Wash it off immediately.

With reservoir cap removed, when depressing brake pedal, brake fluid will spray.

NOTE: If any work is done on brake system or if air in brake lines is suspected, bleed air from the system. When bleeding, keep the amount of fluid in reservoir between Min. and Max. Use only SAE J1703 or FMVSS No. 116 DOT 3 brake fluid.

BRAKE BLEEDING SEQUENCE

For correct bleeding sequence, see BRAKELINE BLEEDING SEQUENCE table. BRAKELINE BLEEDING SEQUENCE

Application

Sequence

Sequoia

Right Rear, Left Rear, Right Front, Left Front

BLEEDING PROCEDURES

CAUTION: DO NOT allow reservoir to run dry during brake bleeding procedure. Use only clean brake fluid. Ensure no dirt or other foreign matter contaminates brake fluid. DO NOT mix different types of brake fluid, as they may not be compatible. DO NOT spill brake fluid on vehicle, as it may damage paint. If brake fluid contacts paint, immediately wash with water.

WARNING: On Traction Control System (TRAC), brake fluid is under high pressure, and may cause personal injury. When repairing master cylinder or TRAC system, carefully bleed air out of TRAC system.

2002-04 BRAKES Disc - Sequoia

For bleeding procedure, see Fig. 1 .

For bleeding procedure, see Fig. 1 .

Toyota Brake Oil

Fig. 1: Brake Fluid Bleeding Procedure

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

Fig. 1: Brake Fluid Bleeding Procedure

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

ADJUSTMENTS

BRAKE PEDAL HEIGHT, FREE PLAY, PEDAL RESERVE DISTANCE & STOP LAMP SWITCH

2002-04 BRAKES Disc - Sequoia

For all brake pedal adjustment procedures, see Fig. 2 . For specifications, see BRAKE PEDAL HEIGHT & FREE PLAY SPECIFICATIONS table, STOP LIGHT SWITCH CLEARANCE table and BRAKE PEDAL MINIMUM RESERVE DISTANCE SPECIFICATIONS table. For torque specifications, see TORQUE SPECIFICATIONS .

BRAKE PEDAL HEIGHT & FREE PLAY SPEC

IFICATIONS

Application

In. (mm)

Brake Pedal Height

5.949-6.50 (151.1-165.1)

Brake Pedal Free Play

0.04-0.24 (1-6)

STOP LIGHT SWITCH CLEARANCE

Application

In. (mm)

Sequoia

.02-.095 (.5-2.4)

MINIMUM BRAKE PEDAL RESERVE DISTAN

CE SPECIFICATIONS

Application

(1) In. (mm)

Sequoia

3.74 (95)

(1) With 110 lbs. (50 kg) applied.

2002-04 BRAKES Disc - Sequoia

2001 Toyota Corolla Brake Pedal Arm
Fig. 2: Brake Pedal Adjustment Procedure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 BRAKES Disc - Sequoia

BRAKE PEDAL RESERVE DISTANCE

For check pedal reserve distance procedure, see BRAKE PEDAL HEIGHT, FREE PLAY, PEDAL

RESERVE DISTANCE & STOP LAMP SWITCH under ADJUSTMENTS.

DISC RUNOUT

1. Remove front wheel.

2. Remove caliper support assembly and suspend aside.

3. Install and tighten 3 hub nuts to specification. See TORQUE SPECIFICATIONS .

4. Using a dial indicator, measure disc runout. See Fig. 3 .

5. Make a note of runout and compare to specification. See DISC BRAKE SPECIFICATIONS .

6. If disc runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout. Maximum runout should not exceed .002 in. (.05 mm). If the bearing play and axle hub runout are normal, go to next step.

7. If minimum runout recorded is greater than specification, replace disc. It is possible to adjust disc runout by grinding it with an "on-car" brake lathe.

8. After repairs, install torque plate and tighten 2 bolts to specification. See TORQUE SPECIFICATIONS .

2002-04 BRAKES Disc - Sequoia

2006 Toyota Bolt Tightening Torque Specs

G00185200

Fig. 3: Inspecting Disc Runout

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

PARKING BRAKE PEDAL

For parking brake pedal adjustment procedure, see Fig. 4 . For component view, see Fig. 5 . For adjusting rear brake shoe clearance procedure, see PARKING BRAKE SHOE CLEARANCE .

2002-04 BRAKES Disc - Sequoia

Prius Parking Brake Adjustment
Fig. 4: Parking Brake Pedal Adjustment Procedure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 BRAKES Disc - Sequoia

Sequoia Brake Booster
Fig. 5: Locating Parking Brake Pedal Assembly Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

PARKING BRAKE SHOE CLEARANCE

1. Temporarily install lug nuts.

2002-04 BRAKES Disc - Sequoia

2. Remove parking brake adjuster access plug.

3. Turn adjuster and expand shoes until disc locks. See Fig. 6 .

4. Back off adjuster 8 notches.

5. Install access plug.

Toyota Landcruiser Handbrake Adjustment
Fig. 6: Adjusting Parking Brake Shoe Clearance Courtesy of BMW OF NORTH AMERICA, INC.

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  • pervinca
    Where is the the starter on a 2002 toyota rav4 located?
    8 years ago
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    How does the MR2 parking brake adjuster work?
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  • abrha
    How to remove the guide pin boots on toyota sequoia?
    1 year ago

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