Page 3049 of 4323
SA2348
SST
Z00641
SST
W04006
R02482
SST
R13226
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA±45
3041 Author: Date:
2005 SEQUOIA (RM1146U)
11. REMOVE OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal.
SST 09308±10010
(b) Remove the oil slinger.
12. REMOVE REAR BEARING AND BEARING SPACER
(a) Using SST, remove the rear bearing from the drive pinion.
SST 09556±22010
(b) Remove the bearing spacer.
13. REMOVE SIDE BEARING RETAINER
Remove the 10 bolts and tap out the retainer with a plastic ham-
mer.
14. REMOVE DIFFERENTIAL CASE ASSEMBLY
15. REMOVE DRIVE PINION FROM DIFFERENTIAL CAR-
RIER
16. REMOVE DRIVE PINION FRONT BEARING
Using SST and a press, remove the bearing and washer from
the drive pinion.
SST 09950±00020
HINT:
If the drive pinion or ring gear is damaged, replace them as a
set.
17. REMOVE DRIVE PINION BEARING OUTER RACES
(a) Using a brass bar and hammer, remove the front bearing
outer race.
Page 3050 of 4323

R13210
SST
R13211F14774
SSTSST
R13213
SSTSST
FA1998
Matchmarks
R11392
SST
SST SA±46
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
3042 Author: Date:
2005 SEQUOIA (RM1146U)
(b) Using SST, remove the rear bearing outer race.
SST 09502±12010, 09612±65014 (09612±01020,
09612±01050)
18. REMOVE SIDE BEARING OUTER RACES
HINT:
Measure the plate washer thickness and note it down.
Tag the bearing outer races to show the location for reas-
sembling.
(a) Using SST and a press, remove the plate washer and out-
er race from the bearing retainer.
SST 09950±60010 (09951±00650),
09950±70010 (09951±07150)
(b) Using SST and a press, remove the plate washer and out-
er race from the differential carrier.
SST 09950±60010 (09951±00650),
09950±70010 (09951±07150)
19. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Using a screwdriver and hammer, unstake the 5 lock
plates.
(c) Remove the 10 bolts and 5 lock plates.
(d) Using a plastic hammer, tap on the ring gear to separate
it from the differential case.
20. REMOVE SIDE BEARINGS
Using SST, remove the 2 side bearings from the differential
case.
SST 09950±40011 (09951±04010, 09952±04010,
09953±04020, 09954±04010, 09955±04061,
09957±04010, 09958±04011),
09950±60010 (09951±00480)
HINT:
Fix the claws of SST to the notch in the differential case.
Page 3051 of 4323
RA0997
SA0353
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA±47
3043 Author: Date:
2005 SEQUOIA (RM1146U)
21. DISASSEMBLE DIFFERENTIAL CASE ASSEMBLY
(a) Using a pin punch and hammer, remove the straight pin.
(b) Remove the pinion shaft, 2 pinion gears, pinion gear
thrust washers, side gears and side gear thrust washers
from the differential case.
22. REMOVE BEARINGS
Using a brass bar and hammer, remove the 2 bearings.
Page 3052 of 4323
SA24R±02
R04465
SST Socket Wrench
R04348
SST
Z03857
R13199
SST
R13422
SA±48
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
3044 Author: Date:
2005 SEQUOIA (RM1146U)
REPLACEMENT
1. REPLACE COMPANION FLANGE DUST DEFLECTOR,
IF NECESSARY
(a) Using SST, a socket wrench and a press, remove the dust
deflector.
SST 09950±00020
(b) Using SST and a press, install a new dust deflector.
SST 09636±20010
2. REPLACE INTERMEDIATE SHAFT NO. 2, IF NEC-
ESSARY
(a) Remove the clutch hub.
(1) Using a snap ring expander, remove the snap ring.
(2) Remove the clutch hub from the intermediate shaft
No. 2.
(b) Remove the oil seal.
Using SST, remove the oil seal from the tube.
SST 09308±00010
(c) Remove the intermediate shaft No. 2 from the tube.
(1) Using needle nose pliers, remove the snap ring.
(2) Remove the shaft from the tube.
(d) Remove the intermediate shaft No. 2 bearing.
(1) Using a snap ring expander, remove the snap ring.
Page 3053 of 4323
R13420
SST
R13421
SST
R13419
SST
5.5 ± 0.3 mm
(0.217 ± 0.012 in.)
SA0335
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA±49
3045 Author: Date:
2005 SEQUOIA (RM1146U)
(2) Using SST, a brass bar and press, remove the bear-
ing.
SST 09950±00020
(e) Install a new intermediate shaft No. 2 bearing.
(1) Using SST and a press, install a new bearing.
SST 09309±37010
(2) Using a snap ring expander, install a new snap ring.
(f) Install the intermediate shaft No. 2 to the tube.
(1) Install the shaft into the tube.
(2) Using needle nose pliers, install a new snap ring.
(g) Install a new oil seal.
(1) Using SST and a plastic hammer, install a new oil
seal.
SST 09223±15020
Oil seal drive in depth: 5.5 ± 0.3 mm (0.217 ± 0.012 in.)
(2) Coat the oil seal lip with MP grease.
(h) Install the clutch hub.
(1) Install the clutch hub to the shaft.
(2) Using a snap ring expander, install a new snap ring.
Page 3054 of 4323

SA0355
SST
0.3 ± 0.3 mm
(0.012 ± 0.012 in.)
SA23O±04
FA1121
F14731
FA1124
SA±50
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
3046 Author: Date:
2005 SEQUOIA (RM1146U)
REASSEMBLY
1. INSTALL NEW BEARINGS
Using SST and a press, install 2 new bearings.
SST 09950±60010 (09951±00380)
Bearing press in depth:
0.3 ± 0.3 mm (0.012 ± 0.012 in.)
2. ASSEMBLE DIFFERENTIAL CASE
(a) Install the 2 thrust washers on the side gears.
(b) Install the 2 side gears, pinion gears, pinion gear thrust
washers and pinion shaft in the differential case.
HINT:
Align the holes for the straight pin in the differential case and
pinion shaft.
(c) Measure the side gear backlash.
(1) Install the intermediate shaft No. 1 to the differential
case.
(2) Using a dial indicator, measure the side gear back-
lash while holding one pinion gear toward the differ-
ential case.
Backlash: 0 ± 0.20 mm (0 ± 0.0079 in.)
If the backlash is not within the specified value, replace the side
gear thrust washer with an appropriate thickness.
HINT:
Refer to the following table to select thrust washers which will
ensure that the backlash is within the specified value.
Washer thickness:
Thickness mm (in.)Thickness mm (in.)
0.96 ± 1.04 (0.0378 ± 0.0409)1.16 ± 1.24 (0.0457 ± 0.0488)
1.06 ± 1.14 (0.0417 ± 0.0449)1.26 ± 1.34 (0.0496 ± 0.0528)
(3) Remove the intermediate shaft No. 1.
3. INSTALL STRAIGHT PIN AND STAKE DIFFERENTIAL
CASE
(a) Using a pin punch and hammer, install the straight pin
through the differential case and hole in the pinion shaft.
(b) Stake the differential case.
4. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and
ring gear.
Page 3055 of 4323

SA2160
Boiling Water
Z02483
R13784
SST
R13375
SST
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA±51
3047 Author: Date:
2005 SEQUOIA (RM1146U)
(b) Heat the ring gear to about 100°C (212°F) in boiling wa-
ter.
(c) Carefully take the ring gear out of the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the ring gear and differential case.
(e) Temporarily install 5 new lock plates and 10 bolts so that
the bolt holes in the ring gear and differential case are
aligned.
(f) After the ring gear has cooled sufficiently, torque the ring
gear set bolts.
Torque: 97 N´m (985 kgf´cm, 71 ft´lbf)
(g) Using a chisel and hammer, stake the 5 lock plates.
HINT:
Stake the claws of the lock plates to fix the bolts. For the claw
contacting the protruding portion of the bolt, stake only the half
of it along the tightening direction.
5. INSTALL SIDE BEARINGS
Using SST and a press, install the bearings into the differential
case.
SST 09226±10010
6. INSTALL SIDE BEARING OUTER RACES
If replacing the side bearings, fit the thinnest new plate washers
to each bearing outer race.
If reusing the bearings, fit the new washers with the same thick-
ness as the washer which was removed.
(a) Install a new plate washer to the side bearing retainer.
(b) Using SST and a press, install the bearing outer race.
SST 09950±60020 (09951±00790),
09950±70010 (09951±07150)
(c) Install a new plate washer to the differential carrier.
Page 3056 of 4323

R13376
SST
R13281
SST
Front bearing
outer race:Rear bearing
outer race:
R01197
SST
R11163
SST SA±52
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
3048 Author: Date:
2005 SEQUOIA (RM1146U)
(d) Using SST and a press, install the bearing outer race.
SST 09950±60020 (09951±00790),
09950±70010 (09951±07150)
7. INSTALL DRIVE PINION FRONT AND REAR BEARING
OUTER RACES
Using SST, install the 2 outer races.
SST 09570±22011
8. INSTALL DRIVE PINION FRONT BEARING
(a) Install the washer on the drive pinion.
HINT:
First fit a washer with the same thickness as the washer which
was removed, then after checking the tooth contact pattern, re-
place the washer with a different thickness if necessary.
(b) Using SST and a press, install the front bearing onto the
drive pinion.
SST 09506±30012
9. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion, rear bearing and oil slinger.
HINT:
After adjusting the ring gear tooth contact pattern, assemble the
spacer and oil seal.
(b) Using SST, install the companion flange.
SST 09950±30012 (09951±03010, 09953±03010,
09954±03010, 09955±03030, 09956±03020)
(c) Coat the threads of the nut with hypoid gear oil.