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Home >> Toyota >> 2000 >> 4Runner Base, 4WD >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Differentials & Axle Shafts - Rear Separate Carrier >> Overhaul >> Differential Assembly (TACOMA & 4RUNNER) >> Reassembly & Adjustments

Reassembly & Adjustments

  1. Using press, press NEW dust deflector on companion flange (if removed).
  2. Install spider, side gears, pinion gears and thrust washers in right differential case. Using dial indicator, check side gear backlash in 4 locations, while holding one side gear against differential case. See Figure or Figure . Check side gear backlash in left and right differential cases.
  3. Side gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS . If side gear backlash is not within specification, install different thickness thrust washer onto both side gears and recheck side gear backlash. Thrust washer is available in various thickness.
  4. Once correct side gear backlash is obtained, coat components with gear oil. Assemble right and left differential cases with reference mark aligned. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS .
  5. Using press, install NEW side bearings onto differential case (if removed). If installing ring gear, heat ring gear to 212°F (100°C) in boiling water.
  6. Remove ring gear from water and allow moisture to evaporate. Install ring gear on differential case with reference marks aligned. Install lock plates (if equipped) onto differential case.
  7. Loosely install all ring gear bolts, with thread lock applied, to ensure bolt holes are aligned. Allow ring gear to cool.
    CAUTION: DO NOT tighten ring gear bolts to specification until ring gear has cooled.
  8. Once ring gear has cooled, tighten ring gear bolts in a crisscross pattern to specification. See TORQUE SPECIFICATIONS . Bend tabs on lock plates (if equipped) against ring gear bolts.
  9. Reinstall differential case with side bearings and races into 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 .
  10. Using dial indicator, check ring gear runout while rotating differential case. Replace ring gear and pinion gear if runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS . Remove differential case and components from differential carrier.
  11. Using a hammer and brass drift, install NEW oil storage ring. Using press, install NEW outer races for front and rear bearings in differential carrier (if removed). If installing NEW rear bearing on drive pinion, install washer on drive pinion. Press rear bearing on drive pinion.
  12. Install drive pinion, front bearing and oil slinger in differential carrier. DO NOT install spacer and oil seal at this time.
  13. Install companion flange on drive pinion. Coat threads of drive pinion nut with oil. Install drive pinion nut onto drive pinion. Hold companion flange and slightly tighten drive pinion nut in small increments.
    CAUTION: When tightening drive pinion nut, DO NOT overtighten nut, as spacer is not installed on drive pinion. Drive pinion nut must be tightened until correct drive pinion rotating torque is obtained. See AXLE ASSEMBLY SPECIFICATIONS .
  14. Turn drive pinion clockwise and counterclockwise several times. Using 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. Tighten drive pinion nut until correct drive pinion rotating torque is obtained. See AXLE ASSEMBLY SPECIFICATIONS .
  15. Apply grease to shift fork rack and connecting part of indicator switch. Insert shift fork into differential carrier. Install outer races onto side bearings. Ensure bearing races are installed on original side bearings. Install adjusting nuts and left side sleeve. Ensure sleeve moves smoothly. Install differential case into differential carrier with aligning shift fork in groove of sleeve. Ensure backlash exists between ring gear and drive pinion.
  16. Install side bearing caps in original location with reference marks aligned. Install bearing cap bolts about 3 revolutions and press side bearing caps downward.
  17. If bearing caps do not seat tightly on differential carrier, adjusting nuts are not properly threaded into differential carrier. Remove adjusting nuts and reinstall (if necessary).
  18. Tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS . Loosen bearing cap bolts until side bearing cap bolts can be rotated by hand.
  19. Fully tighten side bearing cap bolts by hand. Tighten adjusting nut on backside (opposite ring gear teeth) until ring gear has a backlash of about .008" (0.20 mm).
  20. While rotating ring gear, fully tighten adjusting nut on front side (teeth side of ring gear) to fully seat bearings. Loosen adjusting nut on front side (teeth side of ring gear).
  21. Position dial indicator on differential carrier with stem resting against top of adjusting nut on backside (opposite ring gear teeth). Tighten adjusting nut on front side (teeth side of ring gear) until dial indicator starts to move.
  22. Tighten adjusting nut on front side (teeth side of ring gear) an additional 1 to 1 1/2 notches.
  23. Using dial indicator, check ring gear backlash. Ring gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .
  24. If ring gear backlash is not within specification, rotate both adjusting nuts same amount. For example, if adjusting nut on front side (teeth side of ring gear) is loosened one notch, adjusting nut on backside (opposite ring gear teeth) must be tightened one notch. Ensure adjusting nuts are moved same amount to maintain proper bearing preload.
  25. Once correct gear backlash is obtained, tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS . Recheck ring gear backlash.
  26. Using INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to rotate drive pinion and ring gear. Total assembled preload should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .
  27. Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. If gear tooth contact pattern is incorrect, change thickness of washer installed on drive pinion.
  28. Remove drive pinion nut. Using puller, remove companion flange from drive pinion. Remove front bearing and oil slinger from differential carrier.
  29. Install NEW spacer onto drive pinion. Install front bearing and oil slinger onto drive pinion. Use installer tool and companion flange to fully install bearing. Remove companion flange.
  30. Install NEW oil seal to correct depth on differential carrier. See DRIVE PINION OIL SEAL DEPTH INSTALLATION SPECIFICATIONS  table.
  31. Apply grease to lip of oil seal. Install companion flange onto drive pinion. Apply grease to threads of NEW drive pinion nut. Install washer and drive pinion nut onto drive pinion.
  32. Tighten drive pinion nut to minimum specification. See TORQUE SPECIFICATIONS . Using INCH-lb. torque wrench installed onto drive pinion nut, measure drive pinion rotating torque required to start rotation of drive pinion to determine drive pinion bearing preload. Drive pinion rotating torque should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .
  33. If drive pinion rotating torque exceeds specification, replace spacer and repeat procedure. If drive pinion rotating torque is less than specified, tighten drive pinion nut in small increments until correct rotating torque is obtained. DO NOT exceed maximum drive pinion nut torque. If maximum torque is exceeded, replace spacer and repeat procedure. DO NOT back off drive pinion nut.
  34. Recheck ring gear backlash and gear tooth contact pattern. Using dial indicator, check vertical and lateral runout on companion flange while rotating companion flange. See Figure. If vertical or lateral runout exceeds .0039" (0.100 mm), check bearing on drive pinion.
  35. Once all specifications are correct, stake drive pinion nut against drive pinion. Install adjusting nut lock on each bearing cap. Install and tighten bolts to specification.
  36. Apply grease to fork shaft. Install fork shaft. Align fork shaft screw plug holes with holes on shift fork. Place a bead of RTV sealant to shaft retainer. See Fig 1. Apply adhesive to bolt threads, and install shaft retainer bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
  37. Using a punch and hammer, install slotted spring pin into shift lock. Push shift fork into lock position. See Fig 2. Install ball, compression spring and spring seat. Apply adhesive to screw plug, and install and tighten plugs. See TORQUE SPECIFICATIONS .
  38. Measure distance between sleeve and tip of differential case when differential is in free position and in locked position. See Fig 3. Distance should be 1.276-1.335" (32.41-33.91 mm) with differential in free position, and .687-.743" (17.45-18.87 mm) with differential in locked position. Install indicator switch and NEW gasket. See TORQUE SPECIFICATIONS .
  39. Verify outermost rack tooth of shift fork is above center line of actuator installation hole. See Fig 4. Apply 1.5 volts to actuator connector terminals No. 2 (Light Green/Red wire) and No. 3 (Light Green wire). Actuator pinion should rotate about 108 degrees counterclockwise from top of center line of actuator. See Fig 5. Reverse polarity. Actuator should rotate back to near original position.
  40. Insert actuator so that long hole on actuator side fits with knock pin on carrier side. See Fig 6. DO NOT damage "O" ring of actuator. Align actuator with long hole. Rotate actuator counterclockwise when knock pin reaches right side. Install actuator to differential carrier with bolt so that outermost rack tooth of shift fork will fit reference marks of pinion of actuator.
  41. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS . Fill differential. Ensure electronic locking differential operates properly.
Fig 1: Identifying RTV Sealant Location On Shaft Retainer
G97G08160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Installing Shift Fork Into Differential Case
G97I08689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Measuring Distance Between Sleeve & Tip Of Differential Case
G97A08685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 4: Identifying Rack Tooth Location
G97E08692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 5: Checking Actuator Pinion Operation
G97C08691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 6: Identifying Knock Pin Location
G97C08686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002


  1. Using press, press NEW dust deflector onto companion flange (if removed).
  2. On Tacoma, install side gears with thrust washers, pinion gears, thrust washers and pinion shaft into differential case. Ensure hole in pinion shaft aligns with hole for pin in differential case.
  3. On 4Runner, install side gear thrust washer to side gear. Install side gear to right differential case. Install 4 pinion gears and thrust washers to spider. Install 4 pinion gears, with spider, to right differential case. See Figure.
  4. On Tacoma, recheck side gear backlash while holding one pinion gear toward differential case. See AXLE ASSEMBLY SPECIFICATIONS . See Figure or Figure .
  5. If side gear backlash is not within specification, install different thickness thrust washers on side gears, and recheck side gear backlash. Thrust washer is available in various thickness.
  6. Once correct side gear backlash is obtained, install pin in differential case. Using hammer and punch, stake differential case at pin location.
  7. On 4Runner, install spider, side gears, pinion gears and thrust washers into right differential case. Using dial indicator, check side gear backlash while holding one side gear against differential case. See Figure. Check side gear backlash in left and right differential cases.
  8. Side gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS . If side gear backlash is not within specification, install different thickness thrust washer onto both side gears and recheck side gear backlash. Thrust washer is available in various thickness.
  9. Once correct side gear backlash is obtained, coat components with gear oil. Assemble right and left differential cases with reference mark aligned. Install and tighten bolts, in small increments, to specification. See TORQUE SPECIFICATIONS .
  10. On all models, using press, install NEW side bearings onto differential case (if removed). If installing ring gear, heat ring gear to 212°F (100°C) in boiling water.
  11. Remove ring gear from water and allow moisture to evaporate. Install ring gear onto differential case with reference marks aligned. Install lock plates (if equipped) on differential case.
  12. Loosely install all ring gear bolts, with thread lock applied, to ensure bolt holes are aligned. Allow ring gear to cool.
    CAUTION: DO NOT tighten ring gear bolts to specification until ring gear has cooled.
  13. Once ring gear has cooled, tighten ring gear bolts in a crisscross pattern to specification. Bend tabs on lock plates (if equipped) against ring gear bolts.
  14. Install differential case into carrier and tighten adjust nut enough to ensure no play exists in bearing. Install bearing caps. Using dial indicator, measure runout of ring gear. See Figure. See AXLE ASSEMBLY SPECIFICATIONS . Remove bearing caps and differential case.
  15. Using press, install NEW races for front and rear bearings into differential carrier (if removed). Install oil storage ring, on 4Runner. If installing NEW rear bearing onto drive pinion, install washer with same thickness as removed. Press rear bearing onto drive pinion.
  16. Install drive pinion, front bearing and oil slinger (if equipped) into differential carrier. DO NOT install spacer and oil seal at this time.
  17. Install companion flange onto drive pinion. Coat threads of drive pinion nut with oil. Install drive pinion nut onto drive pinion.
  18. Drive pinion nut will be tightened in small increments to obtain correct drive pinion rotating torque. Hold companion flange and slightly tighten drive pinion nut in small increments.
    CAUTION: When tightening drive pinion nut, DO NOT overtighten nut, as spacer is not installed on drive pinion. Drive pinion nut must be tightened until correct drive pinion rotating torque is obtained.
  19. Using 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. Tighten drive pinion nut until correct drive pinion rotating torque is obtained. See AXLE ASSEMBLY SPECIFICATIONS .
  20. Install bearing races on side bearings. Ensure bearing races are installed on original side bearings. Install differential case in differential carrier. Ensure backlash exists between ring gear and drive pinion.
    NOTE: If not equipped with adjusting nuts, go to step  31.
  21. If equipped, install adjusting nuts on differential carrier in original location. Ensure adjusting nuts are properly threaded into differential carrier.
  22. Install side bearing caps in original location with reference marks aligned. Install side bearing cap bolts about 3 revolutions and press side bearing caps downward.
  23. If side bearing caps do not seat tightly on differential carrier, adjusting nuts are not properly threaded into differential carrier. Remove adjusting nuts and reinstall (if necessary).
  24. Tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS . Loosen side bearing cap bolts until side bearing cap bolts can be rotated by hand.
  25. Fully tighten side bearing cap bolts by hand. Tighten adjusting nut on backside (opposite ring gear teeth) until ring gear has a backlash of about .008" (0.20 mm).
  26. While rotating ring gear, fully tighten adjusting nut on front side (teeth side of ring gear) to fully seat bearings. Loosen adjusting nut on front side (teeth side of ring gear).
  27. Position dial indicator on differential carrier with stem resting against top of adjusting nut on backside (opposite ring gear teeth). Tighten adjusting nut on front side (teeth side of ring gear) until dial indicator starts to move.
  28. Tighten adjusting nut on front side (teeth side of ring gear) an additional 1 to 1 1/2 notches. Notches on adjusting nut are openings that adjusting nut lock fits into.
  29. Using dial indicator, check ring gear backlash. Ring gear backlash should be within specification.
  30. If ring gear backlash is not within specification, rotate both adjusting nuts same amount. For example, if adjusting nut on front side (teeth side of ring gear) is loosened one notch, adjusting nut on backside (opposite ring gear teeth) must be tightened one notch. Ensure adjusting nuts are moved same amount to maintain proper bearing preload.
  31. On Tacoma with 2.7L or 3.4L engines, only install plate washer on ring gear back side, leaving some backlash in ring gear. Using plastic hammer, tap ring gear to snug plate washer and bearing into position.
  32. Using dial indicator, hold side bearing boss on teeth surface of ring gear and measure ring gear backlash. See AXLE ASSEMBLY SPECIFICATIONS . Select different thickness plate washer, as needed, using backlash as reference.
  33. Select ring gear teeth side plate washer of thickness to eliminate any clearance between outer race and case. Install plate washer into ring gear back side of carrier. Place other washer on differential case, without outer race, and install case assembly into carrier. Tap with plastic hammer to snug washer and bearing.
  34. Using a dial indicator, re-measure ring gear backlash. It should be .0051-.0071" (.130-.180 mm). If not, increase or decrease thickness of washers on both sides of ring gear by equal amount. Clearance should exist between plate washer and case when backlash is within specification.
  35. When ring gear backlash is properly adjusted, remove teeth side plate washer. With micrometer, measure thickness of plate washer. Install NEW washer that is .0024-.0035" (.061-.089 mm) thicker than plate washer removed. Washer should press into position about 2/3 way by hand. Use brass bar and hammer to fully seat plate washer.
  36. Recheck ring gear backlash to be sure it is within specified range. If not, increase or decrease thickness of washers on both sides of ring gear by equal amount.
    NOTE: Backlash will change about .0008" (.020 mm) for every .0012" (.030 mm) change in plate washer thickness.
  37. Once correct gear backlash is obtained, tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS . Recheck ring gear backlash.
  38. Using INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to rotate drive pinion and ring gear. Total assembled preload should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .
  39. Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. If gear tooth contact pattern is incorrect, change thickness of washer installed on drive pinion.
  40. Remove drive pinion nut. Using puller, remove companion flange from drive pinion.
  41. Remove front bearing and oil slinger (if equipped) from differential carrier. Install NEW spacer and 2 washers (if equipped) on drive pinion. Install front bearing onto drive pinion. Install oil slinger in original direction of installation.
  42. Install NEW oil seal to correct depth in differential carrier. See DRIVE PINION OIL SEAL DEPTH INSTALLATION SPECIFICATIONS  table.
  43. Apply grease to lip of oil seal. Install companion flange onto drive pinion. Apply grease to threads of NEW drive pinion nut. Install washer and drive pinion nut onto drive pinion.
  44. Tighten drive pinion nut to minimum specification. See TORQUE SPECIFICATIONS . Using 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. Drive pinion rotating torque should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .
  45. If drive pinion rotating torque exceeds specification, replace spacer and repeat procedure. If drive pinion rotating torque is less than specified, tighten drive pinion nut in small increments until correct rotating torque is obtained. DO NOT exceed maximum drive pinion nut torque. If maximum torque is exceeded, replace spacer and repeat procedure. DO NOT back off drive pinion nut.
  46. Recheck ring gear backlash and gear tooth contact pattern. Using dial indicator, check vertical and lateral runout on companion flange while rotating companion flange. See Figure. If vertical or lateral runout exceeds .0039" (0.100 mm), check bearing on drive pinion.
  47. Once all specifications are correct, stake drive pinion nut against drive pinion. Install adjusting nut lock on each adjusting nut. Install and tighten bolt to specification.
  48. To complete installation reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS . Fill differential.
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