2009 TOYOTA 4RUNNER Service Repair Manual

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This is the Highly Detailed factory service repair manual for the2009 TOYOTA 4RUNNER, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.2009 TOYOTA 4RUNNER Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: Airbags Audio Visual Axle Brake Control Brakes Charging 1gr Charging 2uz Cooling 1gr Cooling 2uz Cruise Control Differential Driveshaft Electrical Component Locations Emission Control 1gr Emission Control 2uz Engine 1gr Engine 2uz Engine Control 1gr Engine Control 2uz Exhaust 1gr Exhaust 2uz Exterior Fuel 1gr Fuel 2uz Hood Doors Horns Hvac Ignition 1gr Ignition 2uz Instrument Panel Intage 1gr Intake 2uz Interior Trim Lighting Lubrication 1gr Lubrication 2uz Mirrors Navigation Parking Brakes Power Door Locks Power Steering Propeller Shaft Seats Service Specs Starter 1gr Starter 2uz Steering Column Sunroof Suspension Control Suspension Windows Wiper Washer Wiring File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have2009 TOYOTA 4RUNNER Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting!
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  • 1. Airbags1. AudioVisual2. Axle3. BrakeControl4. Brakes5. Charging1gr6. Charging2uz7. Cooling1gr8. Cooling2uz9. CruiseControl10. Differential11. Driveshaft12. ElectricalComponentLocations13. EmissionControl1gr14. EmissionControl2uz15. Engine1gr16. Engine2uz17. EngineControl1gr18. EngineControl2uz19. Exhaust1gr20. Exhaust2uz21. Exterior22. Fuel1gr23. Fuel2uz24. HoodDoors25. Horns26. Hvac27. Ignition1gr28. Ignition2uz29. InstrumentPanel30. Intage1gr31. Intake2uz32. InteriorTrim33. Lighting34. Lubrication1gr35. Lubrication2uz36.
  • 2. Mirrors37. Navigation38. ParkingBrakes39. PowerDoorLocks40. PowerSteering41. PropellerShaft42. Seats43. ServiceSpecs44. Starter1gr45. Starter2uz46. SteeringColumn47. Sunroof48. SuspensionControl49. Suspension50. Windows51. WiperWasher52. Wiring53.
  • 3. 2008 DRIVELINE/AXLES Differential - 4Runner DIFFERENTIAL SYSTEM PRECAUTION 1. Before disassembly, clean the outside of the front and rear differential assembly and remove any sand and mud to prevent it from entering the assembly during disassembly and installation. 2. When removing connected parts made of a light alloy, such as front and rear differential carrier covers, tap them off with a plastic hammer. Do not attempt to pry them off with a screwdriver. 3. Always arrange disassembled parts in order and protect them from dust. 4. Before installation, thoroughly clean and dry each part and then apply hypoid gear oil LSD to it. Do not use alkaline cleaner for aluminum or rubber parts and ring gear set bolts. Also, do not clean rubber parts such as O-rings or oil seals with white gasoline. 5. Coat all sliding surfaces and rotating parts with hypoid gear oil LSD. 6. When holding components in a vice, be sure to place an aluminum sheet under the M part. Do not put them directly in the vice. 7. Be careful not to damage the contact surfaces of the case. Such damage could cause oil leakage. 8. Before applying sealant, remove any deposited oil sealant and clean the part to be sealed using white gasoline. 9. Do not supply oil immediately after installing sealed parts. Leave them for at least an hour. 10. Damage to the surfaces in direct contact with oil seals, O-rings or gaskets could cause oil leakage. Special attention should be paid. 11. When press-fitting an oil seal, be careful not to damage the oil seal lip and outside periphery. 12. When replacing a bearing, replace the inner and outer races as a set. PROBLEM SYMPTOMS TABLE HINT: Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in order. If necessary, replace these parts. DIFFERENTIAL SYSTEM PROBLEM SYMPTOMS CHART Symptom Suspected area Go To Oil leakage from front differential 1. Oil level (Too high or wrong grade) DIFFERENTIAL OIL 2. Front differential rear oil seal (Worn or damaged) INSTALLATION 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:07 PM Page 1 © 2005 Mitchell Repair Information Company, LLC. Microsoft Wednesday, August 05, 2009 3:48:13 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
  • 4. DIFFERENTIAL OIL ADJUSTMENT 1. INSPECT DIFFERENTIAL OIL a. Stop the vehicle on a level place. b. Remove the differential filler plug and gasket. c. Check that the oil level is within 5mm (0 to 0.20 in.) of the bottom of the filler plug opening. 3. Companion flange (Loose or damaged) (1GR-FE) INSTALLATION 4. Companion flange (Loose or damaged) (2UZ-FE) INSTALLATION Oil leakage from rear differential 1. Oil level (Too high or wrong grade) DIFFERENTIAL OIL 2. Rear differential front oil seal (worn or damaged) REMOVAL 3. Companion flange (Loose Or damaged) INSPECTION Oil leak from front drive pinion shaft 1. Oil level (Too high or wrong grade) DIFFERENTIAL OIL 2. Front differential rear oil seal (Worn or damaged) INSTALLATION 3. Companion flange (Loose or damaged) (1GR-FE) INSTALLATION 4. Companion flange (Loose or damaged) (2UZ-FE) INSTALLATION Oil leak from rear drive pinion shaft 1. Oil level (Too high or wrong grade) DIFFERENTIAL OIL 2. Rear differential front oil seal (Worn or damaged) INSTALLATION 3. Companion flange (Loose or damaged) INSTALLATION NOTE:  Excessively large or small quantities of oil may cause problems.  After replacing the oil, drive the vehicle and check the oil level again. 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:07 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
  • 5. Fig. 1: Identifying Differential Oil Level HINT: If necessary, fill the rear differential carrier assembly with hypoid gear oil. Oil grade: Hypoid gear oil API GL-5 Recommended viscosity: Above -18°C (0°F) SAE 90 Below -18°C (0°F) SAE 80W or 80W-90 Capacity: Front differential carrier assembly: 1.35 to 1.45 litters (1.43 to 1.53 US qts, 1.19 to 1.27 Imp. qts) Rear differential carrier assembly 3.00 to 3.10 litters (3.17 to 3.27 US qts, 2.64 to 2.72 Imp. qts) d. Check for oil leakage if the oil level is low. e. Install the differential filler plug and a new gasket. Torque: Front differential carrier assembly 39 N*m (398 kgf*cm, 29 ft.*lbf) Rear differential carrier assembly 49 N*m (500 kgf*cm, 36 ft.*lbf) REAR DIFFERENTIAL CARRIER OIL SEAL 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:07 PM Page 3 © 2005 Mitchell Repair Information Company, LLC.
  • 6. COMPONENTS Fig. 2: Identifying Rear Differential Carrier Oil Seal Components With Torque Specifications REMOVAL 1. DRAIN DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) 2. REMOVE PROPELLER SHAFT ASSEMBLY 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:07 PM Page 4 © 2005 Mitchell Repair Information Company, LLC.
  • 7. a. Place matchmarks on the propeller shaft flange and differential flange. b. 2WD Drive Type: Remove the 4 nuts and 4 washers. c. 4WD Drive Type: Remove the 4 nuts, 4 bolts and 4 washers. d. Suspend the propeller shaft assembly with wire or similar. Fig. 3: Identifying Matchmarks On Propeller Shaft Flange 3. REMOVE REAR DRIVE PINION NUT a. Using SST and a hammer, unstake the nut. SST 09930-00010 Fig. 4: Unstaking Nut b. Using SST to hold the companion flange, remove the nut. SST 09330-00021 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:07 PM Page 5 © 2005 Mitchell Repair Information Company, LLC.
  • 8. Fig. 5: Holding Companion Flange 4. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR a. Using SST, remove the companion flange. SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030) Fig. 6: Removing Companion Flange 5. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL a. Using SST, remove the oil seal. SST 09308-10010 6. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Fig. 7: Removing Oil Seal 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:07 PM Page 6 © 2005 Mitchell Repair Information Company, LLC.
  • 9. 7. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING a. Using SST, remove the front bearing. SST 09556-22010 b. Using SST, remove the front bearing outer race. SST 09308-00010 c. Using a screwdriver, bend the oil storage ring and remove it. 8. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER Fig. 8: Removing Front Bearing Outer Race INSTALLATION 1. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER a. Install a new rear differential drive pinion bearing spacer. 2. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING a. Using a brass bar and a hammer, install a new oil storage ring. b. Using SST and a hammer, install the front bearing outer race. c. Install the front bearing. SST 09316-60011 (09316-00011, 09316-00021) 3. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 4. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL a. Using SST and a hammer, install a new oil seal. SST 09554-30011 Oil seal drive in depth: 0.7 to 1.3 mm (0.0276 to 0.0512 in.) b. Coat oil seal lip with MP grease. 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:08 PM Page 7 © 2005 Mitchell Repair Information Company, LLC.
  • 10. Fig. 9: Installing Oil Seal 5. INSTALL REAR DRIVE COMPANION FLANGE SUB-ASSEMBLY REAR a. Using SST, install the companion flange. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030) b. Coat the threads of a new nut with hypoid gear oil LSD. Fig. 10: Installing Companion Flange c. Using SST to hold the companion flange, tighten the nut. SST 09330-00021 (09330-00030) Torque: 215 N*m (2,190 kgf*cm, 159 ft.*lbf) Fig. 11: Holding Companion Flange 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:08 PM Page 8 © 2005 Mitchell Repair Information Company, LLC.
  • 11. 6. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD a. Using a torque wrench, measure the preload of the backlash between the drive pinion and ring rear. New bearing: 1.05 to 1.64 N*m (10.7 to 16.7 kgf*cm, 9.3 to 14.5 in.*lbf) Reused bearing: 0.56 to 0.85 N*m (5.7 to 8.7 kgf*cm, 5.0 to 7.5 in.*lbf) If necessary, disassemble and inspect the differential assembly. Fig. 12: Measuring Preload Of Backlash Between Drive Pinion And Ring Rear 7. INSTALL REAR DRIVE PINION NUT a. Using a chisel and a hammer, stake the nut. Fig. 13: Staking Nut 8. INSTALL PROPELLER SHAFT ASSEMBLY a. Align the matchmarks on the propeller shaft differential flange. b. 2WD Drive Type: Install the propeller shaft with the 4 washers and 4 nuts. Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) c. 4WD Drive Type: Install the propeller shaft with the 4 bolts, 4 washers and 4 nuts. 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:08 PM Page 9 © 2005 Mitchell Repair Information Company, LLC.
  • 12. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 13. Fig. 14: Identifying Matchmarks On Propeller Shaft Flange Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) 9. FILL UP DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) 10. INSPECT DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL (FOR 4WD) COMPONENTS 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:08 PM Page 10 © 2005 Mitchell Repair Information Company, LLC.
  • 14. Fig. 15: Identifying Differential Side Gear Shaft Oil Seal Components (For 4WD) REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE ENGINE UNDER COVER ASSEMBLY REAR a. Remove the 6 bolts and engine under cover assembly rear. 3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY a. Remove the 4 bolts and No. 1 engine under cover sub-assembly. 4. DRAIN DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) 5. REMOVE FRONT AXLE HUB LH NUT (See REMOVAL ) 6. SEPARATE FRONT SPEED SENSOR LH (See REMOVAL ) 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:08 PM Page 11 © 2005 Mitchell Repair Information Company, LLC.
  • 15. 7. SEPARATE TIE ROD END SUB-ASSEMBLY LH (See REMOVAL ) 8. SEPARATE NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH (See REMOVAL ) 9. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See REMOVAL ) 10. REMOVE DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL a. Using SST, remove the oil seal. SST 09308-00010 Fig. 16: Removing Oil Seal INSTALLATION 1. INSTALL DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL a. Using SST and a hammer, install a new oil seal. SST 09554-30011 b. Coat the oil seal lip with MP grease. 2. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See INSTALLATION ) 3. CONNECT NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH (See INSTALLATION ) Fig. 17: Installing Oil Seal 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:08 PM Page 12 © 2005 Mitchell Repair Information Company, LLC.
  • 16. 4. CONNECT TIE ROD END SUB-ASSEMBLY LH (See INSTALLATION ) 5. CONNECT FRONT SPEED SENSOR LH (See INSTALLATION ) 6. INSTALL FRONT AXLE HUB LH NUT (See INSTALLATION ) 7. FILL UP DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) 8. INSPECT DIFFERENTIAL OIL (See DIFFERENTIAL OIL ) 9. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY a. Install the No. 1 engine under cover sub-assembly with the 4 bolts. 10. INSTALL ENGINE UNDER COVER ASSEMBLY REAR a. Install the engine under cover assembly with the 6 bolts. 11. INSTALL FRONT WHEEL Torque: 112 N*m (1,142 kgf*cm, 83 ft.*lbf) 12. INSPECT ABS SPEED SENSOR SIGNAL HINT: (See TEST MODE PROCEDURE ) 1GR-FE FRONT DIFFERENTIAL CARRIER ASSEMBLY (FOR 4WD) COMPONENTS 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:08 PM Page 13 © 2005 Mitchell Repair Information Company, LLC.
  • 17. Fig. 18: Identifying 1GR-FE Front Differential Carrier Assembly Components With Torque Specifications - For 4WD (1 Of 3) 2008 Toyota 4Runner Limited 2008 DRIVELINE/AXLES Differential - 4Runner Microsoft Wednesday, August 05, 2009 3:48:08 PM Page 14 © 2005 Mitchell Repair Information Company, LLC.
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