Actuator: Service and Repair

DIFFERENTIAL: AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR: REPLACEMENT

REPLACEMENT

1. REMOVE FRONT SIDE MEMBER TO FRONT SUSPENSION CROSSMEMBER BRACE
2. REMOVE NO. 1 ENGINE UNDER COVER
3. REMOVE REAR ENGINE UNDER COVER ASSEMBLY
4. DRAIN DIFFERENTIAL OIL
5. REMOVE AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR

(a) Remove the bolt and disconnect the differential breather tube bracket.
(b) Support the differential with a jack.
(c) Remove differential mounting nut No. 1.
(d) Remove the 2 mounting bolts and 2 nuts.
(e) Disconnect the actuator hose and connector.
(f) Lower the jack.

(g) Remove the 4 bolts and actuator.
6. INSTALL AUTOMATIC DISCONNECTING DIFFERENTIAL ACTUATOR

(a) Remove any old FIPG material.
NOTE: Be careful not to drop oil on the contact surfaces of the actuator and clutch case.

(b) Using gasoline or alcohol, clean any residual FIPG material on the contact surfaces.
(c) Apply FIPG to the differential tube, as shown in the illustration.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
HINT: Install the actuator within 10 minutes of applying FIPG.

(d) Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.
(e) Apply adhesive to 2 or 3 threads at the tip of the bolt.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent
(f) Install the actuator onto the differential tube with the 4 bolts.
Torque: 21 Nm (210 kgf-cm, 15 ft-lbf)

(g) Connect the actuator hose and connector.
(h) Support the differential with a jack.
(i) Install the 2 front mounting bolts and 2 nuts.
Torque: 137 Nm (1,400 kgf-cm, 101 ft-lbf)
(j) Install differential mounting nut No. 1.
Torque: 87 Nm (887 kgf-cm, 64 ft-lbf)
(k) Install the differential breather tube bracket with the bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
7. REFILL DIFFERENTIAL OIL
(a) Refill differential oil Testing and Inspection.
8. CHECK FOR DIFFERENTIAL OIL LEAKAGE
9. INSTALL REAR ENGINE UNDER COVER ASSEMBLY
10. INSTALL NO. 1 ENGINE UNDER COVER
11. INSTALL FRONT SIDE MEMBER TO FRONT SUSPENSION CROSSMEMBER BRACE