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The axle housing assembly consists of a cast-aluminum center section, a removable cast-aluminum axle housing tube (3B210), and a differential housing cover (3N136). Both the axle housing tube and the differential housing cover use silicone sealant as a gasket. The hypoid-design gearset consists of an 8.8-inch ring gear (3A397) and a pinion gear (3N175). Two opposed tapered roller bearings support the drive pinion in the axle housing. A drive pinion collapsible spacer (4662), located on the pinion shaft, maintains pinion bearing preload. The pinion nut adjusts the preload. Differential bearing shims (4A451), located between the differential bearing cups (4221) and the axle housing, adjust the differential bearing preload and the ring gear backlash. The differential case (4205) is a one-piece design with two openings to allow for assembly of the internal components and lubricant flow. Two opposed tapered roller bearings (differential bearings [4221]) support the differential case in the axle housing. Removable differential bearing caps (4224) retain the differential assembly in the axle housing. Inside the differential case, the differential pinion shaft (4211) supports two differential pinion gears (4215). The pinion gears engage the differential side gears (4236), to which the left axle shaft (3A381) and the axle cluster gear shaft (7L253) are splined. The differential pinion shaft bolt retains the differential pinion shaft in the differential case. An embossed metal tag, bolted to the rear face of the RH axle tube, contains front axle identification information. CAUTION: Actuate the front drive axle with the wheels in a straight ahead position, and at light throttle only. A front axle actuator motor assembly (7G360), controlled by an instrument panel-mounted switch, actuates the front drive axle.

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SYMPTOM A screech or whine from the rear differential when making a tight turn at low speed (for example, in a parking lot when 4WD engages). PROBABLE CAUSE The differential fluid is contaminated or broken down, providing insufficient lubrication. CORRECTIVE ACTION Replace the dual pump fluid, and test-drive the vehicle. If necessary, replace the rear differential clutch, replace the oil pump assembly (1997 model only), and add a flow collar. REPAIR PROCEDURE 1. Drain and refill the rear differential with Dual Pump Fluid. 2. Check the tires for proper inflation (recommended cold inflation front and rear is 26 psi) and any variation in tire size or type. 3. Test-drive the vehicle in a parking lot. Make tight, low-speed turns. • If the noise is eliminated, return the vehicle to the customer. • If the noise is still present, go to step 4. 4. Remove the rear differential assembly (see page 15-16 of the 1997–01 CR-V Service Manual). 5. Remove the torque control differential case, then remove and discard the 30 mm shim and the clutch assembly (see steps 1 thru 10 on pages 15-20 thru 15-22 of the service manual).

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Front Axle Will Not Disengage Circuit Description The front axle control circuit consists of an electric motor actuator which engages and disengages the front axle. The front axle actuator motor consists of a permanent magnetic motor, a worm gear controlled plunger, a front axle switch and an electronic control circuit all within the actuator assembly. The front axle actuator consists of the following circuits: The front axle control circuit, which is also connected to the transfer case shift control module The front axle switch circuit, which is also connected to the transfer case shift control module A battery feed circuit A ground circuit When a shift to AUTO 4WD, 4HI or 4LO is requested, the transfer case shift control module engages the front axle by grounding the front axle control circuit through a current limiting driver. Diagnostic Aids A mechanical condition inside the front axle could prevent the shift fork from moving causing the motor to be stuck in one position. Refer to Symptoms – Front Drive Axle See: Differential Assembly\Testing and Inspection\Symptom Related Diagnostic Procedures\Diagnosis By Symptom – Front Drive Axle\- Symptoms – Front Drive Axle

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Use the following field–fix procedure if water is present on the floor carpeting and it can be confirmed that the leak is from the front cowl seam. S 2005 model year Tacoma vehicles. 1. Remove wiper arms and plastic cowl cover. For further removal instructions, refer to the Technical Information System (TIS): 2005 model year Tacoma Repair Manual: Wiper & Washer: Windshield Wiper Motor Assy: Replacement. 2. Locate the left and right front cowl seam and wet area with Toyota Glass Cleaner. Refer to Figure 1 for the location of the left front cowl seam. NOTE: Soapy water can be substituted for Toyota Glass Cleaner. Figure 1 3. Turn the blower motor to the High setting and the air intake selector to Fresh and close all doors and windows on the vehicle. 4. Carefully, inspect the front cowl seam area for air bubbles. S If air bubbles are present, the front cowl seam leak has been confirmed. S If NO air bubbles are present, proceed to Confirmation Procedure for Lower Front Cowl Seam Leak on page 3 of this TSB. 1. If a front cowl seam water leak has been confirmed, locate the left front cowl seam and clean with Kent Acrysolt (or equivalent). Follow the directions on the side of the can carefully. 2. Dry the open seam with compressed air prior to applying sealer. 3. Apply a small bead of seam sealer to the top side of the left front cowl seam as shown in Figure 1. 4. Repeat steps 1 – 3 for the right front cowl seam (if necessary). 5. Allow the seam sealer to dry according to the instructions on the package.

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SYMPTOM A squealing or moaning noise is heard from the rear of the vehicle when the front tires are slipping during acceleration or when the vehicle is turning. PROBABLE CAUSE Water entered the differential through the breather tube and contaminated the differential fluid. CORRECTIVE ACTION Flush the differential with new fluid and/or replace the differential clutch set. PARTS INFORMATION Breather Tube Assembly: P/N 41130-P6R-020 Differential Clutch Set: P/N 48010-P6R-305 Rear Differential Mounting Bracket: P/N 50710-S10-A01 Honda Dual Pump Fluid: P/N 08200-9002 DIAGNOSIS 1. Test-drive the vehicle on a dirt or gravel road. From a stop, accelerate hard to make the front tires slip. • If the rear differential makes noise, go to the REPAIR PROCEDURE. • If the rear differential does not make noise, go to step 2.2. Test-drive the vehicle in a circle on a paved, open parking lot at about 10 mph while holding the steering wheel in a full-lock position. • If the rear differential makes noise, go to the REPAIR PROCEDURE. • If the rear differential does not make noise, disregard this bulletin and troubleshoot other causes. REPAIR PROCEDURE 1. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or Neutral) until the radiator fan comes on. 2. Raise the vehicle on a hoist. 3. Circulate the Dual Pump Fluid through the clutch assembly: • On A/T models: Apply the parking brake, put the transmission into D4, and let the vehicle idle for 5 minutes. • On M/T models: Put the transmission into 1st gear and engage the clutch. Slowly apply the parking brake until just before the engine stalls. Let the engine run like this for 5 minutes. 4. Engage both differential pumps: • On A/T models: Release the parking brake, and let the vehicle idle in D4 for 5 minutes. • On M/T models: Release the parking brake, and let the vehicle idle in 3rd or 4th gear for 5 minutes.