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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 (Tundra) >> Reassembly & Adjustments

Reassembly & Adjustments

  1. Using press, press NEW dust deflector on companion flange (if removed). Install side gears, pinion gears, thrust washers and pinion shaft in differential case. Ensure hole in pinion shaft aligns with hole for pin in differential case.
  2. Recheck side gear backlash. Ensure side gear backlash is within specification. See AXLE ASSEMBLY SPECIFICATIONS .
  3. If side gear backlash is not within specification, install different thickness thrust washers on side gears and recheck side gear backlash. Thrust washers are available in thicknesses from .0590" (1.50 mm) to .0748" (1.90 mm), in .020" (.50 mm) increments.
  4. Once correct side gear backlash is obtained, install pin in differential case. Using hammer and punch, stake differential case at pin location.
  5. Using press, install NEW side bearings on 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 onto differential case with reference marks aligned. Ensure ring gear bolt holes are aligned. Allow ring gear to cool.
    CAUTION: DO NOT tighten ring gear bolts to specification until ring gear has cooled.
  7. Apply thread sealant to threads of ring gear bolts. Once ring gear has cooled, install and tighten ring gear bolts in a crisscross pattern to specification. See TORQUE SPECIFICATIONS .
  8. Using press, press NEW race for front bearing into differential carrier (if removed). Install NEW adjusting washer in differential carrier, below race for rear bearing (if removed). Ensure adjusting washer is same thickness as adjusting washer that was removed.
  9. Using press, press NEW race for rear bearing into differential carrier (if removed). Press NEW rear bearing onto drive pinion (if removed).
  10. Install drive pinion into differential carrier. Support rear side of drive pinion in press. Install front bearing onto drive pinion. DO NOT install spacers, washers and oil seal at this time.
  11. Press front bearing onto drive pinion. Install companion flange onto drive pinion. Coat threads of drive pinion nut with oil. Install drive pinion nut onto drive pinion.
  12. 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.
  13. 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 .
  14. Install bearing races onto side bearings. Ensure bearing races are installed on original side bearings. Install differential case into differential carrier.
  15. Install original plate washer between bearing race and differential carrier on backside of ring gear (opposite teeth side). Ensure ring gear backlash exists. DO NOT install plate washer onto teeth side of ring gear at this time.
  16. Using soft-face hammer, ensure plate washer and differential case and bearing races are seated in differential carrier. Hold side bearing and race on teeth side of ring gear.
  17. Using dial indicator, check ring gear backlash. Ring gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .
  18. If ring gear backlash is not within specification, install different thickness plate washer to obtain correct ring gear backlash. Increase or decrease thickness of washers on both sides by an equal amount.
  19. Once correct ring gear backlash is obtained, select proper thickness plate washer that will eliminate any clearance between bearing race and differential case on teeth side of ring gear. Remove plate washers, differential case and bearing races.
  20. Install plate washer for backside of ring gear (opposite teeth side) into differential carrier. Install differential case, side bearing races and plate washer on teeth side of ring gear into differential carrier. Using soft-face hammer, tap differential case and bearing races into place.
  21. Using dial indicator, check ring gear backlash. Ensure ring gear backlash is within specification. See AXLE ASSEMBLY SPECIFICATIONS .
  22. If ring gear backlash is not within specification, increase or decrease thickness of plate washers same amount on both sides. Changing thickness of plate washer by .0012" (.030 mm) will change ring gear backlash about .0008" (.020 mm).
  23. Ensure no clearance exists between plate washers and differential carrier. Once correct ring gear backlash is obtained, side bearing preload must be set.
  24. To set side bearing preload, remove plate washer from teeth side of ring gear. Measure thickness of plate washer. Select plate washer that is .0024-.0035" (.061-.089 mm) thicker than plate washer removed. Ensure plate washer can be installed 2/3 of way by-hand.
  25. Using soft-face hammer, tap thrust plate into differential carrier. Using dial indicator, recheck ring gear backlash. Ensure ring gear backlash is still within specification. Readjust ring gear backlash if necessary.
  26. Once correct ring gear backlash is obtained, install side bearing cap assembly onto differential carrier. Ensure side bearing cap assembly is installed in original location and reference marks are aligned. Install and tighten side bearing cap assembly bolts to specification. See TORQUE SPECIFICATIONS .
  27. 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 .
  28. Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. If gear tooth contact pattern is incorrect, change thickness of adjusting washer installed on drive pinion.
  29. Remove pinion nut. Using puller, remove companion flange from drive pinion. Using puller, remove front bearing from drive pinion. Install NEW spacer onto drive pinion. Install 2 washers onto drive pinion. See Figure.
  30. Install front bearing onto drive pinion. Support rear side of drive pinion in press. Press front bearing onto drive pinion.
  31. Install NEW oil seal in differential carrier. Ensure surface of oil seal is even with surface of differential carrier. Apply grease to lip of oil seal.
  32. Install companion flange onto drive pinion. Coat threads of NEW drive pinion nut with oil. Install drive pinion nut onto drive pinion.
  33. 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 .
  34. 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.
  35. Install differential case, bearing races and plate washers into differential carrier. Install side bearing cap assembly onto differential carrier. Ensure side bearing cap assembly is installed in original location and reference marks are aligned.
  36. Install and tighten side bearing cap assembly bolts to specification. 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 .
  37. 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 .0035" (.089 mm), check bearing on drive pinion. Once all specifications are correct, stake drive pinion nut against drive pinion.
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