Differential Locking System: Installation

1. Clean contacting surfaces of any FIPG material using gasoline or alcohol.
2. Apply FIPG to the actuator.

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

   HINT:

   Install the actuator within 10 minutes after applying FIPG.

   Fig 1: Applying FIPG To Actuator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the actuator to the differential and match the shaft with the shaft fork hole.
4. Clean the threads of the set bolt and shaft fork with the white gasoline.
5. Coat the threads of the set bolt with adhesive.

   Adhesive: 

   Part No. 08833-00070, THREE BOND 1324 or equivalent 

6. Tighten the shift fork set bolt.

   Torque: 20 N.m (200 kgf.cm, 15 ft.lbf) 

   Fig 2: Installing Shift Fork Set Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Tighten the 4 bolts uniformly, a little at time.

   Torque: 24 N.m (240 kgf.cm, 18 ft.lbf) 

   Fig 3: Tightening Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Clean the contacting surfaces of any FIPG material using gasoline or alcohol.
2. Apply FIPG to the cover.

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

   HINT:

   Install the cover within 10 minutes after applying FIPG.

   Fig 4: Applying FIPG To Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cover with the 3 bolts.

   Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

Install the diff. lock position switch with a new gasket.

Torque: 40 N.m (410 kgf.cm, 30 ft.lbf) 

HINT:

• The depth of the insertion of the bleeder tube into the hose is approx. 15 mm (0.59 in.).
• Take care that the water or the equivalent will not adhere to the connectors and hose.

Install the No. 2 actuator protector with the 2 nuts.

Torque: 36 N.m (367 kgf.cm, 27 ft.lbf) 

Install the No. 1 actuator protector with the nut and bolt.

Torque: 15 N.m (150 kgf.cm, 11 ft.lbf) 

1. Connect the cable to the negative terminal of the battery.
2. Turn the ignition switch to the ON position.
3. Turn the differential lock control switch to the OFF position and cancel the differential lock.
4. Shift the transfer shift lever to H position.