Revolution Gear & Axle 86-89 Toyota Gen4 Pickup 7.5in IFS 45mm Ring & Pinion Master Install Kit
Regearing a 1986-1989 Toyota 4WD Pickup or first-generation 4Runner for 31 or 33 inch tires means opening the front differential as well as the rear, and the front 7.5 inch IFS unit on these early trucks takes its own bearing size. The Revolution Gear and Axle 35-2042 is the master install kit for that early front diff, the version with 45mm carrier bearings. It is also the right box when the front diff howls in 4WD, the pinion seal weeps onto the skid plate, or the yoke has developed play after decades of use.
On the 1986-and-later IFS trucks the front differential is a separate third member bolted to the frame, feeding the front wheels through CV shafts. When the transfer case is in 4WD, the front driveshaft spins the pinion, the pinion drives the 7.5 inch ring gear, and the carrier spins on two tapered side bearings. Pinion depth, pinion preload and carrier position are all set by shims and a crush sleeve, so every one of those parts has to be fresh when gears change. Revolution lists this kit with Timken pinion and carrier bearings, a pinion seal, a crush sleeve, pinion shims, ring gear bolts and cover gasket or silicone. Axle seals are not included, and Revolution marks carrier shims as not applicable for this kit, so keep your original carrier shims as a starting point and plan for a shim kit if your setup needs a change in carrier position.
Year is the main check. Toyota changed the front diff carrier bearing size for 1990, which is why Revolution sells a separate 50mm version of this kit for 1990-up trucks. On a used truck with a swapped front diff, measure the carrier bearing or read the part number off the old bearing. Lift the front, put it in 4WD neutral, and rock the pinion flange: clunks and play point at bearings and preload. If you are regearing, the front and rear must match exactly. A truck that came with 4.10 gears needs a new ratio in both the 7.5 front and the 8 inch rear.
Revolution lists 35-2042 for the Toyota 7.5 inch IFS front with 45mm carrier bearings: the 1986-89 four-cylinder and V6 fourth-generation Pickup and the 1984-89 first-generation 4Runner. In practice that means the 1986-89 IFS 4Runner, since earlier models had a solid front axle. It does not fit the 1990-95 Pickup and 4Runner 50mm front, the Tacoma, T100 or Tundra 7.5 IFS, or any 8 inch rear axle. If you are not sure what is under your truck, send us the year and VIN. More gear install parts are in our rebuild kits category.
For gears, the Revolution Toyota 7.5 4.88 set is the common 33 inch choice, and the USA Standard 7.5 4.56 set suits 31s. Match the rear with an 8 inch set such as the Revolution Toyota 8 inch 4.88 set, or the 8 inch 5.29 set for 35s and heavy crawling, after confirming your rear spline count and that the front ratio you need is available. Revolution's setup chart lists the Toyota 7.5 at a 0.095 inch starting pinion shim, 12-15 in-lb pinion bearing preload with new bearings, 0.006-0.010 inch backlash, 70 ft-lb ring gear bolts and 70 ft-lb bearing caps. Paint the teeth and read the pattern before final assembly, using our backlash and pinion depth guide. Fill with GL-5 gear oil (Revolution's break-in guidance calls for a conventional 80W-90 or 85W-140 for the first fill) and follow the break-in procedure, including an early oil change. For common failure points on this axle, see our Toyota 7.5 IFS problems and rebuild cost guide.
| Brand | Revolution Gear & Axle |
| Part number | 35-2042 |
| Fits | Revolution Gear & Axle 86-89 Toyota Gen4 Pickup 7.5in IFS 45mm Ring & Pinion Master Install Kit |
| Vehicle fitment | Toyota Gen4 Pickup (1986-1989) |
| Type | Differential Install Kits |
| Condition | New |
| Ships | Same business day (in stock), from the USA |
| Warranty | 1-year |
Doing this repair right usually means replacing these at the same time. Same transmission, ships together.
No. Toyota moved to 50mm carrier bearings in the 7.5 IFS front for 1990, and Revolution sells a separate 50mm kit for those trucks. 35-2042 is the 45mm kit for 1986-89.
Revolution lists Timken pinion and carrier bearings, pinion seal, crush sleeve, pinion shims, ring gear bolts and cover gasket or silicone. Axle seals are not included and carrier shims are listed as not applicable.
Yes, if you change the front ratio. On a 4WD Toyota the front 7.5 and rear 8 inch must run the same ratio or the drivetrain binds in 4WD.
No. The 1995-and-later Tacoma, T100 and early Tundra 7.5 IFS fronts use different bearings and gears. This kit is for the 1986-89 Pickup and 4Runner 45mm front.
A GL-5 gear oil. Revolution recommends a conventional, non-synthetic 80W-90 or 85W-140 for break-in, then an oil change at about 500 miles to flush out wear material from the new gears.
No. A crush sleeve only sets preload once. The kit includes a new one so the pinion preload can be set correctly with new bearings.
