Toyota 4Runner 2001-06

Pinion Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the differential oil.
  4.  
  5. Remove or disconnect the following:

    Driveshaft by matchmarking it
     
    Companion flange nut, by loosen the staked portion
     
    Companion flange, using a screw-type extractor
     
    Oil seal, using an extractor
     

  6.  

To install:

  1. Install a new oil seal, to a depth of 0.059 in. (1.5mm) below the lip, using a seal driver.
  2.  
  3. Lubricate the seal lip with multi-purpose grease.
  4.  
  5. Install or connect the following:

    Companion flange, coat the threads with multi-purpose grease
     
    New companion flange nut. Tighten it to 89 ft. lbs. (120 Nm).
     

  6.  
  7. Measure the bearing preload, using a torque wrench. The correct preload should be 5-9 inch lbs. (0.6-1.0 Nm) for a used bearing or 10-17 inch lbs. (1-2 Nm) for a new bearing.
  8.  


NOTE
If the preload is greater that specified, replace the bearing spacer. If the preload is less than specified, tighten the companion flange nut in 9 ft. lbs. (13 Nm) increments until the correct preload is achieved. Maximum torque for the nut is 165 ft. lbs. (223 Nm). If the value is exceeded, the bearing spacer must be replaced; do not back off the flange nut to lower the torque or preload.

  1. Install the driveshaft by aligning the matchmarks.
  2.  
  3. Check the companion flange run-out; maximum allowable run-out is 0.003 in. (0.10mm).
  4.  
  5. Stake the pinion flange nut.
  6.  
  7. Refill the differential with oil.
  8.  

  1. Raise and safely support the vehicle.
  2.  
  3. Matchmark the flanges on the driveshaft and pinion. Disconnect the driveshaft from the differential.
  4.  
  5. Use a hammer and small chisel to loosen the staking on the companion flange bolt. Attach a counter-holding tool to the companion flange and remove the nut. Use the proper threaded extractor to remove the companion flange.
  6.  
  7. Use an extractor to remove the oil seal and oil slinger from the housing.
  8.  

To install:

  1. Make certain the new seal faces in the correct direction. Install the new seal with a driver or seal installation tool of the correct diameter. Drive the new seal in until it is recessed 0.039 in. (1.0mm) in the housing.
  2.  
  3. Coat the inner lip of the seal with multi-purpose grease. Install the companion flange (and washer, if removed). Apply a light coat of oil to the threads of a NEW companion flange nut.
  4.  
  5. Set up the counter-holding tool and install the companion flange nut. Tighten the nut as follows:

    2001-02: 145 ft. lbs. (196 Nm)
     
    2003-05: 159 ft. lbs. (215 Nm)
     

  6.  
  7. Check the drive pinion preload with a torque wrench. Correct preload using a new bearing should be:

    2001-02: 8.7-13.9 inch lbs. (0.9-1.6 Nm)
     
    2003-05: 9.3-14.5 inch lbs. (1.05-1.64 Nm)
     

  8.  
  9. If the preload is greater than specified, the bearing spacer must be removed and replaced inside the pinion housing. Do NOT back off the companion flange nut to relieve the pressure. If the preload is less than specified (the usual case), retighten the companion flange nut in increments of 9 ft. lbs. (13 Nm) until the correct specification is reached.
  10.  
  11. Maximum allowable torque on the nut, under any condition, is 253 ft. lbs. (343 Nm).
    CAUTION
    Take great care not to exceed either the preload limit or the maximum torque on the nut.

  12.  
  13. Stake the drive pinion nut.
  14.  
  15. Connect the rear propeller shaft, aligning the matchmarks.
  16.  
  17. Lower the vehicle to the ground; inspect the fluid level in the axle.
  18.  

 
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