AXLE AND DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): REASSEMBLY (2008 Sequoia)

Last Modified: 11-29-2007		1.6 A
Service Category: Drivetrain	Section: Axle/Differential
Model Year: 2008	Model: Sequoia	Doc ID: RM0000016GD00QX
Title: AXLE AND DIFFERENTIAL: FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD): REASSEMBLY (2008 Sequoia)

REASSEMBLY

1. INSTALL STRAIGHT PIN

(a) Using a plastic-faced hammer, tap in the straight pins until their protrusion amounts are at the specified values shown in the illustration below.

Standard:

Item

for Straight Pin A

19.5 to 20.5 mm

(0.768 to 0.808 in.)

9.991 to 10.000 mm

(0.3936 to 0.3940 in.)

9.5 to 10.0 mm

(0.374 to 0.394 in.)

for Straight Pin B

15.6 to 15.8 mm

(0.615 to 0.623 in.)

3.995 to 4.000 mm

(0.1574 to 0.3940 in.)

5.6 to 6.2 mm

(0.221 to 0.244 in.)

2. INSTALL FRONT DIFFERENTIAL SIDE GEAR SHAFT RH BEARING

(a) Using SST and a press, press in the bearing.

SST: 09223-00010

(b) Using a snap ring expander, install a new 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 a new snap ring.

4. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Using SST and a plastic-faced hammer, tap in a new oil seal.

SST: 09608-32010

Standard oil seal depth:

4.8 to 5.8 mm (0.189 to 0.228 in.)

(b) Coat the lip of the oil seal with MP grease.

5. INSTALL DIFFERENTIAL CLUTCH HUB

(a) Install the clutch hub onto the side gear inter shaft.

(b) Using snap ring pliers, install a new snap ring.

NOTICE:

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

6. INSTALL FRONT DIFFERENTIAL SIDE GEAR NEEDLE ROLLER BEARING

(a) Using SST and a press, press in 2 new bearings.

SST: 09950-60010

09951-00420

Standard bearing depth:

1.2 to 1.8 mm (0.0472 to 0.0709 in.)

7. INSTALL FRONT DIFFERENTIAL CASE

(a) Install the 2 side gear 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:

Thickness	Thickness
1.43 to 1.47 mm (0.0563 to 0.0579 in.)	1.68 to 1.72 mm (0.0661 to 0.0677 in.)
1.48 to 1.52 mm (0.0583 to 0.0598 in.)	1.73 to 1.77 mm (0.0681 to 0.0697 in.)
1.53 to 1.57 mm (0.0602 to 0.0618 in.)	1.78 to 1.82 mm (0.0701 to 0.0717 in.)
1.58 to 1.62 mm (0.0622 to 0.0638 in.)	1.83 to 1.87 mm (0.0720 to 0.0736 in.)
1.63 to 1.67 mm (0.0642 to 0.0657 in.)	-

(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.
Apply hypoid gear oil to each sliding surface and rotating part.

(1) Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the differential case assembly.

Standard backlash:

0 to 0.15 mm (0 to 0.00591 in.)

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

(d) Using a pin punch and hammer, tap in the straight pin through the differential case and hole of the pinion shaft.

(e) Stake the differential case.

8. INSTALL DIFFERENTIAL RING GEAR

(a) Clean the contact surfaces of the differential case and ring gear.

(b) Heat the ring gear to about 100°C (212°F) in boiling water.

(d) After the moisture on the ring gear has completely evaporated, quickly set the ring gear onto the differential case.

HINT:

Align the matchmarks on the ring gear and differential case.
Temporarily install the 10 bolts so that the bolt holes in the ring gear and differential case are aligned.

(e) After the ring gear cools down sufficiently, apply adhesive to the bolts and install them.

Torque: 137 N·m (1397 kgf·cm, 101 ft·lbf)

Adhesive:

Toyota Genuine Adhesive 1360K, Three Bond 1360K or equivalent

9. INSTALL FRONT DIFFERENTIAL CASE BEARING

(a) Using SST and a press, press in the 2 bearings (inner race).

SST: 09316-20011

SST: 09316-60011

09316-00041

10. INSTALL FRONT DIFFERENTIAL CASE BEARING

HINT:

When replacing the 2 differential case bearings, fit the thinnest washer to each bearing. When reusing the bearings, fit a washer of the same thickness as the one removed to each bearing.

(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.

SST: 09950-60020

09951-00890

SST: 09950-70010

09951-07150

(d) Using SST and a press, press in the bearing (outer race) onto the differential carrier assembly.

SST: 09950-60020

09951-00890

SST: 09950-70010

09951-07150

11. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING

SST: 09950-60020

09951-00810

09951-00890

(a) Using SST, install the bearing (outer race).

12. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

SST: 09950-60020

09951-00890

09951-01030

(a) Using SST, install the washer and bearing (outer race).

HINT:

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

13. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING

(a) Using SST and a press, press in the bearing (inner race).

SST: 09506-35010

14. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION

15. INSTALL FRONT DIFFERENTIAL CASE

16. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER

(a) Install the differential cross shaft bearing retainer and differential support with the 14 bolts.

for Bolt A

Torque: 65 N·m (663 kgf·cm, 48 ft·lbf)

for Bolt B

Torque: 155 N·m (1581 kgf·cm, 114 ft·lbf)

17. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING

(a) Using SST and a hammer, lightly tap in the bearing (inner race) to install it.

SST: 09316-60011

09316-00041

18. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

19. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using SST, install the companion flange.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03020

(b) Coat the threads of the nut with hypoid gear oil.

SST: 09330-00021

09330-00030

(d) Tighten the nut until the standard preload is reached.

Torque:

451 N*m (4599 kgf*cm, 332 ft.*lbf) or less

NOTICE:

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

(e) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Standard Preload (at Starting):

Bearing	Specified Condition
New	3.11 to 3.61 Nm (32 to 36 kgfcm, 28 to 31 in.*lbf)
Reused	2.14 to 2.45 Nm (22 to 24 kgfcm, 19 to 21 in.*lbf)

If necessary, disassemble and inspect the differential assembly.

20. ADJUST BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION

(a) Using SST and a dial indicator, measure the ring gear backlash.

SST: 09564-33010

Standard backlash:

0.17 to 0.27 mm (0.00670 to 0.01064 in.)

If the backlash 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.

Washer Thickness:

Thickness	Thickness
1.49 to 1.51 mm (0.0587 to 0.0594 in.)	1.93 to 1.95 mm (0.0760 to 0.0768 in.)
1.51 to 1.53 mm (0.0594 to 0.0602 in.)	1.95 to 1.97 mm (0.0768 to 0.0776 in.)
1.53 to 1.55 mm (0.0602 to 0.0610 in.)	1.97 to 1.99 mm (0.0776 to 0.0783 in.)
1.55 to 1.57 mm (0.0610 to 0.0618 in.)	1.99 to 2.01 mm (0.0783 to 0.0791 in.)
1.57 to 1.59 mm (0.0618 to 0.0626 in.)	2.01 to 2.03 mm (0.0791 to 0.0799 in.)
1.59 to 1.61 mm (0.0626 to 0.0634 in.)	2.03 to 2.05 mm (0.0799 to 0.0807 in.)
1.61 to 1.63 mm (0.0634 to 0.0642 in.)	2.05 to 2.07 mm (0.0807 to 0.0815 in.)
1.63 to 1.65 mm (0.0642 to 0.0650 in.)	2.07 to 2.09 mm (0.0815 to 0.0823 in.)
1.65 to 1.67 mm (0.0650 to 0.0657 in.)	2.09 to 2.11 mm (0.0823 to 0.0831 in.)
1.67 to 1.69 mm (0.0657 to 0.0665 in.)	2.11 to 2.13 mm (0.0831 to 0.0839 in.)
1.69 to 1.71 mm (0.0665 to 0.0673 in.)	2.13 to 2.15 mm (0.0839 to 0.0846 in.)
1.71 to 1.73 mm (0.0673 to 0.0681 in.)	2.15 to 2.17 mm (0.0846 to 0.0854 in.)
1.73 to 1.75 mm (0.0681 to 0.0689 in.)	2.17 to 2.19 mm (0.0854 to 0.0862 in.)
1.75 to 1.77 mm (0.0689 to 0.0697 in.)	2.19 to 2.21 mm (0.0862 to 0.0870 in.)
1.77 to 1.79 mm (0.0697 to 0.0705 in.)	2.21 to 2.23 mm (0.0870 to 0.0878 in.)
1.79 to 1.81 mm (0.0705 to 0.0713 in.)	2.23 to 2.25 mm (0.0878 to 0.0886 in.)
1.81 to 1.83 mm (0.0713 to 0.0720 in.)	2.25 to 2.27 mm (0.0886 to 0.0894 in.)
1.83 to 1.85 mm (0.0720 to 0.0728 in.)	2.27 to 2.29 mm (0.0894 to 0.0902 in.)
1.85 to 1.87 mm (0.0728 to 0.0736 in.)	2.29 to 2.31 mm (0.0902 to 0.0909 in.)
1.87 to 1.89 mm (0.0736 to 0.0744 in.)	2.31 to 2.33 mm (0.0909 to 0.0917 in.)
1.89 to 1.91 mm (0.0744 to 0.0752 in.)	2.33 to 2.35 mm (0.0917 to 0.0925 in.)
1.91 to 1.93 mm (0.0752 to 0.0760 in.)	-

21. INSPECT TOTAL PRELOAD

(a) Using a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.

Standard total preload (at starting):

Standard drive pinion preload plus 0.20 to 0.63 N*m (3 to 6 kgf*cm, 2 to 5 in.*lbf)

If necessary, disassemble and inspect the differential.

22. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION

(a) Remove the bearing retainer and differential case.

(b) Coat 3 or 4 teeth at 3 different positions on the ring gear with Prussian blue.

(d) Install the differential cross shaft bearing retainer and front differential front support assembly LH with the 14 bolts.

for Bolt A

Torque: 65 N·m (633 kgf·cm, 48 ft·lbf)

for Bolt B

Torque: 155 N·m (1581 kgf·cm, 114 ft·lbf)

(e) Hold the companion flange firmly and rotate the ring gear in both directions.

(f) Remove the differential case, side bearing retainer and differential case.

(g) Inspect the tooth contact pattern.

If the teeth are not engaged properly, use the following chart to select the appropriate washer for correction.

Washer Thickness:

Thickness	Thickness
1.815 to 1.835 mm (0.0715 to 0.0722 in.)	2.065 to 2.085 mm (0.0813 to 0.0821 in.)
1.840 to 1.860 mm (0.0724 to 0.0732 in.)	2.090 to 2.110 mm (0.0823 to 0.0831 in.)
1.865 to 1.885 mm (0.0734 to 0.0742 in.)	2.115 to 2.135 mm (0.0793 to 0.0841 in.)
1.890 to 1.910 mm (0.0744 to 0.0752 in.)	2.140 to 2.160 mm (0.0843 to 0.0850 in.)
1.915 to 1.935 mm (0.0754 to 0.0762 in.)	2.165 to 2.185 mm (0.0852 to 0.0860 in.)
1.940 to 1.960 mm (0.0764 to 0.0772 in.)	2.190 to 2.210 mm (0.0862 to 0.0870 in.)
1.965 to 1.985 mm (0.0774 to 0.0781 in.)	2.215 to 2.235 mm (0.0872 to 0.0870 in.)
1.990 to 2.010 mm (0.0783 to 0.0791 in.)	2.240 to 2.260 mm (0.0882 to 0.0890 in.)
2.015 to 2.035 mm (0.0793 to 0.0801 in.)	2.265 to 2.285 mm (0.0892 to 0.0900 in.)
2.040 to 2.060 mm (0.0803 to 0.0811 in.)	-

23. REMOVE FRONT DRIVE PINION FRONT COMPANION FLANGE SUB-ASSEMBLY

24. REMOVE FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

25. REMOVE FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER

26. REMOVE FRONT DIFFERENTIAL CASE

27. REMOVE DIFFERENTIAL DRIVE PINION

28. REMOVE FRONT DRIVE PINION FRONT RADIAL BALL BEARING

29. INSTALL FRONT DIFFERENTIAL DRIVE PINION BEARING SPACER

(a) Install a new bearing spacer.

30. TEMPORARILY INSTALL DIFFERENTIAL DRIVE PINION

31. INSTALL FRONT DIFFERENTIAL CASE

32. INSTALL FRONT DIFFERENTIAL CROSS SHAFT BEARING RETAINER

(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and side bearing retainer.

(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

HINT:

Install the side bearing retainer within 10 minutes of applying seal packing.

(d) Install the front differential cross shaft bearing retainer and front differential front support assembly LH with the 11 bolts (A), and 3 bolts (B).

for Bolt A

Torque: 65 N·m (663 kgf·cm, 48 ft·lbf)

for Bolt B

Torque: 155 N·m (1581 kgf·cm, 114 ft·lbf)

33. INSTALL FRONT DRIVE PINION FRONT RADIAL BALL BEARING

(a) Using SST and a hammer, lightly tap in the bearing (inner race) to install it.

SST: 09316-60011

09316-00041

34. INSTALL FRONT DIFFERENTIAL DRIVE PINION OIL SLINGER

35. INSTALL FRONT DIFFERENTIAL CARRIER OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal.

SST: 09502-12010

SST: 09316-60011

09316-00041

Standard oil seal depth:

5.6 to 6.6 mm (0.221 to 0.260 in.)

(b) Coat the lip of the oil seal with MP grease.

36. INSTALL FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY FRONT

(a) Using SST, install the companion flange.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

09956-03020

37. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD

(a) Using SST to hold the companion flange.

SST: 09330-00021

09330-00030

(b) Coat the threads of a new nut with hypoid gear oil.

Torque:

451 N*m (4599 kgf*cm, 332 ft.*lbf) or less

(d) Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.

Standard Preload (at Starting):

Bearing	Specified Condition
New	3.11 to 3.61 Nm (32 to 36 kgfcm, 28 to 31 in.*lbf)
Reused	2.14 to 2.45 Nm (22 to 24 kgfcm, 19 to 21 in.*lbf)

If the preload is greater than the specification, replace the bearing spacer.

If the preload is less than the specification, retighten the nut with 13 N*m (130 kgf*cm, 9 ft.*lbf) of torque at a time until the specified preload is reached.

Torque:

451 N*m (4599 kgf*cm, 332 ft.*lbf) or less

If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure.

HINT:

Do not loosen the nut to reduce the preload.

38. INSPECT TOTAL PRELOAD

(a) With the drive pinion contacting the tooth side of the ring gear, use a torque wrench to measure the total preload.

Standard total preload (at starting):

Standard drive pinion preload plus 1.33 to 2.13 N*m (14 to 21 kgf*cm 12 to 18 in.*lbf)

39. INSPECT BACKLASH BETWEEN DIFFERENTIAL RING GEAR AND DIFFERENTIAL DRIVE PINION

(a) Using SST and a dial indicator, measure the ring gear backlash.

SST: 09564-33010

Standard backlash:

0.17 to 0.27 mm (0.00670 to 0.0106 in.)

40. INSPECT RUNOUT OF FRONT DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

(a) Using a dial indicator, measure the runout of the companion flange vertically and laterally.

Maximum Runout:

Runout	Specified Condition
Vertical runout	0.10 mm (0.00394 in.)
Lateral runout	0.10 mm (0.00394 in.)

If the runout is greater than the maximum, replace the companion flange.

41. STAKE FRONT DRIVE PINION COMPANION FLANGE FRONT NUT

(a) Using a chisel and hammer, stake the nut.

42. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL

(a) Using SST and a plastic-faced hammer, tap in a new oil seal until its surface is flush with the differential carrier end.

SST: 09608-32010

(b) Coat the lip of the oil seal with MP grease.

Standard oil seal depth:

-0.45 to 0.45 mm (-0.0177 to 0.0177 in.)

43. INSTALL DIFFERENTIAL SIDE GEAR INTER SHAFT SUB-ASSEMBLY

(a) Install a new snap ring onto the side gear inter shaft.

(b) Using a plastic-faced hammer, install the side gear inter shaft onto the differential case.

(d) Check that the side gear inter shaft does not come out when trying to pull it out by hand.

44. INSTALL FRONT DIFFERENTIAL TUBE ASSEMBLY

(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and bearing retainer.

(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

HINT:

Install the differential tube within 10 minutes of applying seal packing.

(d) Install the differential tube onto the bearing retainer.

(e) Clean the threads of 4 new bolts and the retainer bolt holes with toluene or trichloroethylene.

(f) Apply adhesive to 2 to 3 threads of each bolt end.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(g) Install the 4 bolts.

Torque:

65 N*m (663 kgf*cm, 48 ft.*lbf) or less

45. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR

(a) Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential tube and actuator.

(b) Clean the contact surfaces with any residual FIPG material using gasoline or alcohol.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

HINT:

Install the actuator within 10 minutes of applying seal packing.

(d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

(e) Install the actuator onto the differential tube.

(f) Apply adhesive to 2 to 3 threads of each bolt end.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(g) Install the 4 bolts.

Torque: 21 N·m (210 kgf·cm, 16 ft·lbf)