Page 3057 of 4323

SA2347
SST
SA2352
R12683
SST
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA±53
3049 Author: Date:
2005 SEQUOIA (RM1146U)
(d) Using SST to hold the flange, tighten the nut.
HINT:
Adjust the drive pinion preload by tightening the companion
flange nut.
SST 09330±00021
NOTICE:
As there is no spacer, tighten the nut a little at a time and
be careful not to overtighten it.
(e) Using a torque wrench, measure the preload of the drive
pinion using the backlash between the drive pinion and
ring gear.
Preload (at starting):
New bearing
1.1 ± 1.8 N´m (11 ± 18 kgf´cm, 9.7 ± 15.9 in.´lbf)
Reused bearing
0.5 ± 0.9 N´m (5 ± 9 kgf´cm, 4.4 ± 8.0 in.´lbf)
10. INSTALL DIFFERENTIAL CASE IN DIFFERENTIAL
CARRIER
11. ADJUST RING GEAR BACKLASH
(a) Install the side bearing retainer with the 10 bolts.
Torque: 69 N´m (700 kgf´cm, 51 ft´lbf)
HINT:
Rotate the ring gear several times to make the bearing fit.
(b) Using SST and a dial indicator, measure the ring gear
backlash.
SST 09564±32011
Backlash: 0.1 ± 0.18 mm (0.0039 ± 0.0071 in.)
If the backlash is not within the specified value, adjust it by ei-
ther increasing or decreasing the thickness of plate washers on
both sides by an equal amount.
HINT:
There should be no clearance between the plate washer and
case. Ensure that there is ring gear backlash.
Page 3058 of 4323

R13220
SA±54
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
3050 Author: Date:
2005 SEQUOIA (RM1146U)
Washer thickness:
Thickness mm (in.)Thickness mm (in.)Thickness mm (in.)
2.00 ± 2.02 (0.0787 ± 0.0795)2.27 ± 2.29 (0.0894 ± 0.0902)2.54 ± 2.56 (0.1000 ± 0.1008)
2.03 ± 2.05 (0.0799 ± 0.0807)2.30 ± 2.32 (0.0906 ± 0.0913)2.57 ± 2.59 (0.1012 ± 0.1020)
2.06 ± 2.08 (0.0811 ± 0.0819)2.33 ± 2.35 (0.0917 ± 0.0925)2.60 ± 2.62 (0.1024 ± 0.1031)
2.09 ± 2.11 (0.0823 ± 0.0831)2.36 ± 2.38 (0.0929 ± 0.0937)2.63 ± 2.65 (0.1035 ± 0.1043)
2.12 ± 2.14 (0.0835 ± 0.0843)2.39 ± 2.41 (0.0941 ± 0.0949)2.66 ± 2.68 (0.1047 ± 0.1055)
2.15 ± 2.17 (0.0846 ± 0.0854)2.42 ± 2.44 (0.0953 ± 0.0961)2.69 ± 2.71 (0.1059 ± 0.1067)
2.18 ± 2.20 (0.0858 ± 0.0866)2.45 ± 2.47 (0.0965 ± 0.0972)2.72 ± 2.74 (0.1071 ± 0.1079)
2.21 ± 2.23 (0.0870 ± 0.0878)2.48 ± 2.50 (0.0976 ± 0.0984)2.75 ± 2.77 (0.1083 ± 0.1091)
2.24 ± 2.26 (0.0882 ± 0.0890)2.51 ± 2.53 (0.0988 ± 0.0996)2.78 ± 2.80 (0.1094 ± 0.1102)
12. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the preload with the teeth of
the drive pinion and ring gear in contact.
Total preload (at starting):
Drive pinion preload plus 0.4 ± 0.6 N´m (4 ± 6 kgf´cm,
3.5 ± 5.2 in.´lbf)
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Remove the 10 bolts, side bearing retainer and differen-
tial case.
(b) Coat 3 or 4 teeth at three different positions on the ring
gear with red lead primer.
(c) Install the differential case and side bearing retainer with
the 10 bolts.
Torque: 69 N´m (700 kgf´cm, 51 ft´lbf)
(d) Hold the companion flange firmly and rotate the ring gear
in both directions.
(e) Remove the 10 bolts, side bearing retainer and differen-
tial case.
(f) Inspect the tooth contact pattern.
Page 3059 of 4323

Z00699
Heel ContactFace Contact
Proper ContactSelect an adjusting washer that will bring the
drive pinion closer to the ring gear.
Toe Contact
Flank Contact
Select an adjusting washer that will shift the
drive pinion away from the ring gear.
FA2008
Washer
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA±55
3051 Author: Date:
2005 SEQUOIA (RM1146U)
If the teeth are not contacting properly, use the following table
to select a proper washer for correction.
Washer thickness:
Thickness mm (in.)Thickness mm (in.)Thickness mm (in.)
1.69 ± 1.71 (0.0665 ± 0.0673)1.93 ± 1.95 (0.0760 ± 0.0768)2.17 ± 2.19 (0.0854 ± 0.0862)
1.72 ± 1.74 (0.0677 ± 0.0685)1.96 ± 1.98 (0.0772 ± 0.0780)2.20 ± 2.22 (0.0866 ± 0.0874)
1.75 ± 1.77 (0.0689 ± 0.0697)1.99 ± 2.01 (0.0783 ± 0.0791)2.23 ± 2.25 (0.0878 ± 0.0886)
1.78 ± 1.80 (0.0701 ± 0.0709)2.02 ± 2.04 (0.0795 ± 0.0803)2.26 ± 2.28 (0.0890 ± 0.0898)
1.81 ± 1.83 (0.0713 ± 0.0720)2.05 ± 2.07 (0.0807 ± 0.0815)2.29 ± 2.31 (0.0902 ± 0.0909)
1.84 ± 1.86 (0.0724 ± 0.0732)2.08 ± 2.10 (0.0819 ± 0.0827)2.32 ± 2.34 (0.0913 ± 0.0921)
1.87 ± 1.89 (0.0736 ± 0.0744)2.11 ± 2.13 (0.0831 ± 0.0839)±
1.90 ± 1.92 (0.0748 ± 0.0756)2.14 ± 2.16 (0.0843 ± 0.0850)±
14. REMOVE COMPANION FLANGE AND OIL SLINGER
(See page SA±43)
15. REMOVE REAR BEARING (See page SA±43)
16. INSTALL NEW BEARING SPACER, REAR BEARING
AND OIL SLINGER
(a) Install a new bearing spacer and place the rear bearing
and oil slinger.
Page 3060 of 4323

R11163SST
R13417
SST
4.5 ± 0.3 mm
(0.177 ± 0.012 in.)
SA2351
SST
SA2352
SA±56
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
3052 Author: Date:
2005 SEQUOIA (RM1146U)
(b) Using SST and the companion flange, install the rear
bearing, then remove the companion flange.
SST 09950±30012 (09951±03010, 09953±03010,
09954±03010, 09955±03030, 09956±03020)
17. INSTALL OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09554±22010
Oil seal drive in depth: 4.5 ± 0.3 mm (0.177 ± 0.012 in.)
(b) Coat the oil seal lip with MP grease.
18. INSTALL COMPANION FLANGE
(a) Place the companion flange on the drive pinion.
(b) Coat the threads of a new nut with hypoid gear oil.
(c) Using SST to hold the flange, torque the nut.
SST 09330±00021
Torque: 108 N´m (1,100 kgf´cm, 80 ft´lbf)
19. ADJUST DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the drive pinion
using the backlash between the drive pinion and the ring gear.
Preload (at starting):
New bearing
1.2 ± 1.9 N´m (12 ± 19 kgf´cm, 10.4 ± 16.5 in.´lbf)
Reused bearing
0.6 ± 1.0 N´m (6 ± 10 kgf´cm, 5.2 ± 8.7 in.´lbf)
If the preload is greater than the specified value, replace the
bearing spacer.
If the preload is less than the specified value, retighten the nut
with 13 N´m (130 kgf´cm, 9 ft´lbf) of torque at a time until the spe-
cified preload is reached.
Torque: 223 N´m (2,275 kgf´cm, 165 ft´lbf) or less
If the torque is exceeded the maximum while retightening the
nut, replace the bearing spacer and repeat the preload adjust-
ing procedure. Do not loosen the nut to reduce the preload.
Page 3061 of 4323

R13200
FIPG
R13416
SST
R13415
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA±57
3053 Author: Date:
2005 SEQUOIA (RM1146U)
20. INSTALL DIFFERENTIAL CASE
21. INSTALL SIDE BEARING RETAINER
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the differential carrier and
side bearing retainer.
(b) Clean both installation surfaces with gasoline or alcohol.
(c) Apply FIPG to the side bearing retainer, as shown in the
illustration.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or
equivalent
HINT:
Install the side bearing retainer within 10 minutes after applying
FIPG.
(d) Install the side bearing retainer with the 10 bolts.
Torque: 69 N´m (700 kgf´cm, 51 ft´lbf)
22. CHECK TOTAL PRELOAD (See step 12.)
23. RECHECK RING GEAR BACKLASH
(See page SA±43)
24. RECHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See step 13.)
25. CHECK COMPANION FLANGE RUNOUT
(See step 1.)
26. STAKE DRIVE PINION NUT
27. INSTALL SIDE OIL SEAL
(a) Using SST and a plastic hammer, install a new oil seal un-
til its surface is flush with the differential carrier end.
SST 09608±32010
(b) Coat the oil seal lip with MP grease.
28. INSTALL INTERMEDIATE SHAFT NO. 1
(a) Install a new snap ring to the shaft.
(b) Using a plastic hammer, install the shaft to the differential
case.
(c) Check that the intermediate shaft will not come out by try-
ing to pull it out by hand.
Page 3062 of 4323

SA0371
R13201
FIPG
F07258
Adhesive
F06634
FIPG
SA±58
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
3054 Author: Date:
2005 SEQUOIA (RM1146U)
29. INSTALL CLUTCH CASE TO DIFFERENTIAL TUBE
(a) Install a new O±ring to the tube.
(b) Coat the O±ring with MP grease.
(c) Install the clutch case to the tube.
(d) Using a torx® socket (E14), torque the 2 torx bolts.
Torque: 78 N´m (800 kgf´cm, 58 ft´lbf)
30. INSTALL CLUTCH SLEEVE
31. INSTALL DIFFERENTIAL TUBE TO DIFFERENTIAL
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the differential and clutch
case.
(b) Clean both installation surfaces with gasoline or alcohol.
(c) Apply FIPG to the differential, as shown in the illustration.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or
equivalent
HINT:
Install the differential tube within 10 minutes after applying
FIPG.
(d) Install the differential tube to the differential.
(e) Clean the threads of the 2 long torx bolts and retainer bolt
holes with toluene or trichlorethylene.
(f) Apply adhesive to 2 or 3 threads of the long bolts end.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(g) Using torx® socket (E14), torque the 4 torx bolts.
Torque: 78 N´m (800 kgf´cm, 58 ft´lbf)
32. INSTALL A.D.D. ACTUATOR
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the actuator and clutch case.
(b) Clean both installation surfaces with gasoline or alcohol.
(c) Apply FIPG to the clutch case, as shown in the illustration.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or
equivalent
HINT:
Install the actuator within 10 minutes after applying FIPG.
(d) Install the A.D.D. actuator with the 4 bolts.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
Page 3063 of 4323

SA14Q±06
± SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER
SA±59
3055 Author: Date:
2005 SEQUOIA (RM1146U)
INSTALLATION
1. INSTALL DIFFERENTIAL MOUNTING CUSHIONS
(a) Install the 2 front mounting cushions with the 5 bolts.
Torque: 157 N´m (1,600 kgf´cm, 116 ft´lbf)
(b) Install the rear mounting cushion with the 2 bolts.
Torque: 108 N´m (1,100 kgf´cm, 80 ft´lbf)
2. INSTALL FRONT DIFFERENTIAL CARRIER
(a) Jack up the front differential.
(b) Install the 2 front mounting bolts.
Torque: 137 N´m (1,400 kgf´cm, 101 ft´lbf)
(c) Using a hexagon (12 mm) wrench, install the rear mounting nut.
Torque: 87 N´m (890 kgf´cm, 64 ft´lbf)
(d) Remove the jack.
3. INSTALL TUBE WITH WIRE HARNESS ASSEMBLY
(a) Install the tube with wire harness assembly with the bolt.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) Connect the actuator connector, vacuum hose and breather hose.
4. CONNECT FRONT PROPELLER SHAFT (See page PR±9)
5. INSTALL DRIVE SHAFTS (See page SA±36)
6. FILL DIFFERENTIAL WITH HYPOID GEAR OIL (See page SA±38)
Page 3064 of 4323
SA23P±03
F16856
4WD Control ECU
2WD/4HI and 4LO Switch
4WD and Center Diff. Lock
Indicator Light
(Combination Meter)
Transfer 4WD
Position Switch
Transfer L4 Position Switch
A.D.D. Actuator
Actuator Connector SA±60
± SUSPENSION AND AXLEA.D.D. CONTROL SYSTEM
3056 Author: Date:
2005 SEQUOIA (RM1146U)
A.D.D. CONTROL SYSTEM
LOCATION