Driver rear axle leaking grease.. what do I fix and how

All the parts - wheel bearings, axle seals, various retainer rings you need - all of those are covered in the link I posted above (and here again, below).

All the special tools you need are also included in that post. Just click the links, close your eyes, and order. It's several hundred dollars for all of it, but (a) you want OEM in this case and (b) it's cheaper than paying some shop to do it.

Replacing My Rear Axle Seals & Bearings – ADVENTURETACO

Parts:

• (2) Dust Seals (90313-48001) - one for each side of the axle
  • '96-'00 4Runner or Tacoma - P/N: (90313-48001)
  • '01-'02 4Runners or '01-'04 Tacoma use P/N: (90313-54001)
• (2) Axle Bearings - one for each side of the axle; oil washes out grease.
  • '96-'00 4Runner or Tacoma - P/N: 90363-40020-77
  • '01-'02 4Runners or '01-'04 Tacoma use P/N: 90363-40068
• (2) Inner seals for axle housing (90310-50006) - these are the actual axle seals
• (2) Axle Housing Tube O-rings (90301-88077) - one for each side of the axle
• (2) Snap rings for retainers (90520-36045) - Optional. Toyota says to replace these when doing the job.
• DOT3 or DOT4 brake fluid
• 3qt 80W-90 Gear oil for rear diff
• Crush washers for rear diff

Special tools.

• from Harbor Freight
• Rear Wheel Axle Bearing Puller & Tone Ring Tool/Installer - used with the shop press to both remove and install various components on the rear axle. Amazing tool, worth twice it's price, and you're supporting a fellow gear head in the process.
• 3” ABS cleanout, with cap - to seat the new rear axle bearing.
• OTC 4507 Seal Driver Kit - to seat the new rear axle seal.
• OTC 4579 Seal Puller Kit - optional, to pull the old rear axle seal; I recommend purchasing this puller - I didn't the first time I did the job, and the seal is a PITA to remove without it. I bought it for the second time (a second truck) and it's worth every penny.

And of course, I used the "normal" tools that we all have around the shop for the various jobs we do on our trucks.

• Floor jack and (2) 6 ton jack stands.
• Misc sockets (I recommend this set from Williams, a Snap-On brand)
  • 10mm socket - to remove the ABS sensor from the axle housing.
  • 14mm deep socket - to remove nuts holding brake drum to axle housing.
  • 24mm socket - to remove diff fill/drain plugs.
  • 5/8" deep socket - to use in the press when pressing on various components.
  • Ratchet, Extensions, and breaker bar as necessary.
• 14mm box end wrench (set) - to remove nuts holding brake drum to axle housing.
• 10mm flare nut wrench (set) - to remove brake line fittings from rear drum.
• Snap ring pliers - to remove/install the snap-ring for the outer retainer.
• 3mm, 4mm, 5mm Allen wrench (set) - to measure placement of the inner retainer on re-installation.
• Assortment of vacuum caps - to prevent brake fluid from leaking out of rear lines once disconnected.
• Brake cleaner - to clean the brake components, as well as axle, throughout the process.
• Grease - for installing new parts.

 

Very Nice!
Thank you

 

Totally agree on this. It's a judgement call. Thing is, one needs to have the experience, technical expertise and tools to make that call.

This bearing was washed free of grease. Likely the only thing sustaining it's life was the gear oil leaking thru it. Also, for clarity, the bearing is "sealed" in bearing nomenclature only. Really just a snug shield. The bearing is lubed by it's own grease. In this case the "leaking" axle shaft seal is inboard and in addition to the integral bearing seals, intended to keep gear oil out of it.


At risk of sounding a little "high in the saddle", I don't mind saying I was part of the online crew that took it upon ourselves to solve the premature and repeated seal failure issue 21+ years ago and we did. One fellow came up with a more "robust" looking aftermarket seal thru a dimensional search. Another came up with an existing Toyota seal with similar attributes. I came up with the revised "bearing retainer" placement and special seal driver/technique. Toyota later adopted both the different seal and the driver bit.
I would advise anyone with a moderate bit of mechanical experience wanting to give this job a try, to check out all to info you can find. The write up and video by @Timmah! and @turbodb already mentioned are probably the best out there. That being said there is a fair bit of "technique" that falls into the category of "accepted/standard shop procedure". No single video, write up, post or thread covers it all.
Here's a few. At the beginning keep an eye out for causes. Like @Wyoming09 mentioned, first check the breather. I'll add check the axle itself (on the truck) for flange run out. One might want to source a replacement before taking the truck out of service. Then there is stuff like using RTV as a pressing lube for at least the inboard bearing retainer. Checking that the inboard retainer is truly perpendicular to the shaft. Simply the act of "pressing it on" does not guarantee its not cocked. Then there are truly trivial bits like most snap or retaining rings are directional in that they should face a certain direction. Of course checking the bare shaft for run out between centers should go with out saying.

After all that, many DIY folks have success while at the same time apparent pros/dealerships screw it up all the time.

Another option for someone like the OP would be pull the axle/brake/bearing assembly, maybe source the parts and take the bunch to a shop for the pressing. One would first need to find such a shop that is experienced with this specific job and can pass a quiz on the details.

 

I don't think there is anything you haven't had to do to your truck before the rest of us stumble upon it.

Such a valuable resource. Thank you.

 

Damn Good!

Im probably going to Bitch out with this repair... My mechanic said he’d do the work, Labor Only, for $170 per side

Damnit! My Fiancé read this^^ and said “So you’re going to admit defeat huh?”

I sure wish we lived up North, or West.
I always see threads where someone says “I’m having trouble fixin’ my truck”
Then someone else is like “hey bro bring it over Saturday with a cooler full of beer, we’ll knock it out in no time” blah blah blah.
Unfortunately, I don’t get that down in East TX. Not too many Vehicular Mountaineers in the piney woods.

 

That's a reasonable price I'd say; similar to/slightly less than the tool cost (though, you won't end up with all the new toys )

 

Unfortunately no new tools, That’s the biggest downside to not doing it myself. Except of course the experience, confidence, and sense of satisfaction you only get from diy

 

Ok so I clicked the links provided and Amazon said the parts don’t fit my truck..
I’m not sure how much I trust their info

 

What are the part numbers that Amazon says don't fit your truck?

 

Having done this on a '00 Tacoma and '97 4Runner, I've only used the parts for those, myself. However, these are most definitely the parts in the 01-04 parts list, and Ben @m3bassman did this on his '01, which should match yours, using my write-up.

 

Is this the rear axle bearing part number that is in your write-up? 90363-40068

 

Yes. (all the part numbers are in post #23 above if you want to check others as well)

 

That is the one the Toyota parts houses that use the truck's vin# say is correct for my '02.

I would recomend using a site that allows you to enter your truck's vin# and use it to verify whether the part you want from Amazon is correct or not.

Here is the one I used: https://www.toyotapartsdeal.com/oem/toyota~bearing~for~rear~axle~shaft~90363-40068.html

I also use:

https://www.toyodiy.com/parts/

https://partsouq.com

 

Nice.
I’m stopping by the Toyota Stealership later today to double check part numbers. After that I’ll order everything listed above.
Thanks a million for the info everyone!!

 

Amazon doesn't even recognize 2002 Tacomas as having 4wd as an option from what I remember reading in another thread awhile back. They wouldn't let someone pick 4wd as an option to verify a CV axle seal part. I would not go off of Amazon's fitment guide, use www.partsouq.com to verify OEM part #s to your VIN