Toyota Pick-ups, Land Cruiser, and 4 Runner 1997-00

Differential Carrier

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REMOVAL & INSTALLATION



4Runner
  1. Remove the engine undercover.
  2.  
  3. Drain the differential oil.
  4.  
  5. Disconnect the front driveshaft.
  6.  



Click image to see an enlarged view

Fig. Exploded view of the front differential assembly4Runner

  1. Place matchmarks on the driveshaft then remove the four nuts, washers and bolts. Disconnect the driveshaft.
  2.  
  3. Remove the front differential as follows:
    1. With Automatic Disconnecting Differential (ADD), disconnect the vacuum hoses, breather hose, ADD switch harness and oil TEMP sensor connector with "2-4" selector.
    2.  
    3. Without ADD, disconnect the breather hose. Remove the two bolts and tube from the differential.
    4.  

  4.  
  5. Support the front differential with a suitable jack.
  6.  
  7. Remove the rear mounting nut and front mounting bolts.
  8.  
  9. Lower the jack, and then remove the front differential assembly.
  10.  
  11. Remove the front and rear mounting cushions.
  12.  

To install:

  1. Attach the front and rear mounting cushions, tighten the rear to 80 ft. lbs. (108 Nm) and the front to 116 ft. lbs. (157 Nm).
  2.  
  3. Raise and support the differential assembly into position.
  4.  
  5. Install the rear mounting nut and front mounting bolts. Tighten the nuts to 64 ft. lbs. (87 Nm) and the bolts to 101 ft. lbs. (137 Nm).
  6.  
  7. On vehicles without ADD, attach the tube to the differential, tighten the mounting bolts to 9 ft. lbs. (13 Nm). Install the breather hose.
  8.  
  9. On vehicles with ADD, attach the vacuum hoses, breather hose, ADD switch harness and oil TEMP sensor connector with "2-4" selector. Attach the tube to the differential, then tighten the mounting bolts to 9 ft. lbs. (13 Nm).
  10.  
  11. Attach the front driveshaft, tighten to 54 ft. lbs. (74 Nm).
  12.  
  13. Install the driveshafts.
  14.  
  15. Install the drain plug if it was removed or double-check its tightness. Install the proper amount of gear oil.
  16.  
  17. Install the engine undercover.
  18.  
  19. Test drive the vehicle.
  20.  

T100
  1. Remove the engine undercover.
  2.  
  3. Drain the differential oil.
  4.  
  5. Disconnect the front driveshaft.
  6.  
  7. Place matchmarks on the driveshaft and remove the six nuts holding the driveshaft and side gear shaft. Remove the driveshaft nuts.
  8.  
  9. Disconnect the vacuum hoses and the 4WD indicator switch harness.
  10.  
  11. Remove the crossmember.
  12.  
  13. Loosen and remove the mounting bolt and nut for the differential.
  14.  
  15. Support the front differential with a suitable jack.
  16.  
  17. Remove the right and left rear mounting bolts. Lower the jack, and then remove the differential assembly.
  18.  

To install:

  1. Support the differential with a jack and raise into position. Install and tighten the right and left mounting bolts to 123 ft. lbs. (167 Nm).
  2.  
  3. Attach the front mounting bolt and nut, tighten to 108 ft. lbs. (147 Nm).
  4.  
  5. Install and attach the crossmember, tighten to 93 ft. lbs. (126 Nm).
  6.  
  7. Attach the vacuum hoses and the 4WD indicator harness.
  8.  
  9. Install and tighten the driveshaft nuts to 61 ft. lbs. (83 Nm).
  10.  
  11. Attach the front driveshaft.
  12.  
  13. Install the drain plug if it was removed or double-check its tightness. Install the proper amount of gear oil.
  14.  
  15. Install the engine undercover.
  16.  
  17. Test drive the vehicle.
  18.  

Tacoma
  1. Remove the engine undercover.
  2.  
  3. Drain the differential oil.
  4.  
  5. Disconnect the front driveshaft.
  6.  



Click image to see an enlarged view

Fig. Exploded view of the front differential assemblyTacoma

  1. Place matchmarks on the driveshaft then remove the four nuts, washers and bolts. Disconnect the driveshaft.
  2.  
  3. Remove the front differential as follows:
    1. With Automatic Disconnecting Differential (ADD), disconnect the vacuum hoses, breather hose, ADD switch harness and oil TEMP sensor connector with "2-4" selector.
    2.  
    3. Without ADD, disconnect the breather hose. Remove the two bolts and tube from the differential.
    4.  

  4.  
  5. Support the front differential with a suitable jack.
  6.  
  7. Remove the rear mounting nut and front mounting bolts.
  8.  
  9. Lower the jack, then remove the front differential assembly.
  10.  
  11. Remove the front and rear mounting cushions.
  12.  

To install:

  1. Attach the front and rear mounting cushions, tighten the rear to 80 ft. lbs. (108 Nm). and the front to 116 ft. lbs. (157 Nm).
  2.  
  3. Raise and support the differential assembly into position.
  4.  
  5. Install the rear mounting nut and front mounting bolts. Tighten the nuts to 64 ft. lbs. (87 Nm) and the bolts to 101 ft. lbs. (137 Nm).
  6.  
  7. On vehicles without ADD, attach the tube to the differential, tighten the mounting bolts to 9 ft. lbs. (13 Nm). Install the breather hose.
  8.  
  9. On vehicles with ADD, attach the vacuum hoses, breather hose, ADD switch harness and oil TEMP sensor connector with "2-4" selector. Attach the tube to the differential, then tighten the mounting bolts to 9 ft. lbs. (13 Nm).
  10.  
  11. Attach the front driveshaft, tighten to 54 ft. lbs. (74 Nm).
  12.  
  13. Install the driveshafts.
  14.  
  15. Install the drain plug if it was removed or double-check its tightness. Install the proper amount of gear oil.
  16.  
  17. Install the engine undercover.
  18.  
  19. Test drive the vehicle.
  20.  

Land Cruiser

Before removal on vehicles with a differential lock, turn the ignition switch to the ON position. Turn the lock switch to the FR/RR position, then lock the front differential. Disconnect the negative battery cable.

  1. Elevate and safely support the vehicle on stands. Double-check the security and placement of the stands.
  2.  
  3. Drain the differential oil.
  4.  
  5. Remove the front axle shafts.
  6.  



Click image to see an enlarged view

Fig. If your vehicle has a differential lock, turn the lock switch to the FR/RR position, then lock the front differential

  1. Remove the cotter pin and castle nut from each end of the steering tie rod. Use a ball joint separator (NEVER a hammer) to separate the tie rod joints; remove the tie rod.
  2.  



Click image to see an enlarged view

Fig. Exploded view of the differential assemblyearly model Land Cruiser shown

  1. Disconnect the front shaft. Make matchmarks first. On vehicles with differential lock, disconnect the harness and tube.
  2.  
  3. Remove the ring of nuts holding the carrier and remove the carrier assembly. Do NOT scratch the machined surfaces during removal.
  4.  

To install:

  1. Place a new gasket in position on the housing. Fit the carrier into the axle and install the nuts. Tighten the nuts to 1820 ft. lbs. (2527 Nm).
  2.  
  3. On vehicles with differential lock, attach the harness and tube.
  4.  
  5. Connect the front driveshaft.
  6.  
  7. Install the tie rod.
  8.  
  9. Install the front driveshafts.
  10.  
  11. Install the drain plug if it was removed or double-check its tightness. Install the proper amount of gear oil. Lower the vehicle to the ground.
  12.  
  13. Test drive the vehicle.
  14.  
  15. Check that the bleeder plug at the point of the bleeder (inside the engine area) is not damaged or worn.
  16.  

 
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