Automatic Disconnecting Differential Actuator Installation

Drivetrain. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
Axle And Differential. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. INSTALL DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY

  2. ADD DIFFERENTIAL OIL

  3. INSTALL NO. 2 ENGINE UNDER COVER

  4. INSTALL NO. 1 ENGINE UNDER COVER

Automatic Disconnecting Differential Actuator -- Installation



1. INSTALL DIFFERENTIAL VACUUM ACTUATOR ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Remove any seal packing material from the contact surface of the differential and clutch case.

    NOTICE:
    Do not drop oil on the contact surfaces.

  1. Clean residual seal packing material from the contact surfaces using gasoline or alcohol.

  1. Apply seal packing to the differential tube as shown.

    Seal packing:
    Toyota Genuine seal packing 1281, Three Bond 1281 or equivalent
    HINT:
    Install the actuator within 3 minutes after applying seal packing.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Clean the threads of the 4 bolts and retainer bolt holes with toluene or trichloroethylene.

  1. Install the actuator to the differential tube.

  1. Install the 4 bolts.

    Torque:
    21 N*m{210 kgf*cm, 15 ft.*lbf}

  1. Connect the actuator hose and connector.

  1. Support the front differential with a jack.

  1. Install the 2 front mounting bolts and 2 nuts.

    Torque:
    137 N*m{1400 kgf*cm, 101 ft.*lbf}

  1. Install the front No. 1 differential mounting nut.

    Torque:
    87 N*m{887 kgf*cm, 64 ft.*lbf}

  1. Install the front differential breather tube bracket with the bolt.

    Torque:
    13 N*m{133 kgf*cm, 10 ft.*lbf}

  1. Lower the jack.



2. ADD DIFFERENTIAL OIL


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Axle And Differential.Axle System.Automatic Disconnecting Differential Actuator Installation

  1. Add differential oil so that the oil level is within 5 mm (0 to 0.196 in.) from the bottom lip of the differential filler plug hole.

    Text in Illustration
    *a
    		0 to 5 mm (0 to 0.196 in.)
    NOTICE:
    1. After changing the oil, drive the vehicle, and then check the oil level again.
    2. Too much or too little oil will lead to differential problems.
    If necessary, fill the differential carrier with hypoid gear oil.
    Recommended Viscosity:
    Item
    		Temperature
    		Viscosity
    Front Differential (w/ A.D.D.)
    		SAE 75W-90
    Front Differential (w/o A.D.D.)
    Rear Differential
    		Above -18°C (0°F)
    		SAE 90
    Below -18°C (0°F)
    		SAE 80W-90 or SAE 80W
    Differential Oil Type:
    Item
    		Oil type
    Front Differential
    Rear Differential
    		Hypoid gear oil API GL-5 or equivalent
    Rear Differential (for LSD)
    		Hypoid gear oil LSD API GL-5 or equivalent
    Standard Front Differential Oil Capacity:
    Item
    		Capacity
    w/o A.D.D.
    		1.40 to 1.50 liters (1.48 to 1.58 US qts., 1.23 to 1.32 Imp. qts.)
    w/ A.D.D.
    		1.60 to 1.70 liters (1.69 to 1.79 US qts., 1.41 to 1.49 Imp. qts.)
    Standard Rear Differential Oil Capacity:
    Item
    		Capacity
    for LSD
    4WD and Pre-runner
    for DANA Made
    		3.30 to 3.40 liters (3.49 to 3.59 US qts., 2.91 to 2.99 Imp. qts.)

  1. Check for oil leakage when the oil level is low.

  1. Install a new gasket and the differential filler plug.

    Torque:
    for front differential:
    39 N*m{400 kgf*cm, 29 ft.*lbf}
    for rear differential:
    49 N*m{500 kgf*cm, 36 ft.*lbf}


3. INSTALL NO. 2 ENGINE UNDER COVER
Torque:
28 N*m{286 kgf*cm, 21 ft.*lbf}


4. INSTALL NO. 1 ENGINE UNDER COVER
Torque:
28 N*m{286 kgf*cm, 21 ft.*lbf}