Tacoma Extra Cab 2WD L4-2438cc 2.4L DOHC MFI (1997)
a. Install a new snap ring to the shaft
b. Using a plastic-faced hammer, install the shaft to the differential case.
c. Check that there is 2 - 3 mm (0.08 - 0.12 inch) of play in axial direction.
d. Check that the intermediate shaft will not come out by trying to pull it completely out by hand.
29. W/ A.D.D.: 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. Torque the 2 torx bolts using Torx socket E14 (Part No. 09044-00010, or locally manufactured tool).
Torque to 78 Nm (58 ft. lbs.)
30. W/ A.D.D.: 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 contacting surfaces of any residual FIPG material using gasoline or alcohol.
c. Apply FIPG: Part No. 08826-00090, THREE BOND 1281, or equivalent, to the differential, as shown.
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 4 bolts (W/O A.D.D.) or 2 torx bolts (W/ A.D.D.) and retainer bolt holes with toluene or trichloroethylene.
f.
Apply adhesive Part No. 08833-00070, THREE BOND 1324, or equivalent, to 2 or 3 threads of the bolts end.
g. Torque the 4 bolts (W/O A.D.D.) or 4 torx bolts (W/ A. D.D.) using Torx socket E14 (Part No. 09044-00010 or locally manufactured tool).
Torque:
W/O A.D.D.: 105 Nm (77 ft. lbs.)
W/ A.D.D.: 78 Nm (58 ft. lbs.)
32. W/ A.D.D.: 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.
