Center Differential: Disassembly

INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE
1. Using a feeler gauge, measure the high speed output gear thrust clearance.
  1. Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
  2. Maximum clearance: 0.25 mm (0.0098 in.)
  Fig 1: Measuring High Speed Output Gear Thrust Clearance Using Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the high speed output gear radial clearance.
  1. Standard clearance: 0.035 - 0.091 mm (0.00138 - 0.00358 in.)
  2. Maximum clearance: 0.091 mm (0.00358 in.)
  Fig 2: Measuring High Speed Output Gear Radial Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE GEAR PIECE
1. Using a snap ring expander, remove the snap ring.
2. Using SST and a press, remove the front drive gear piece.
  1. SST 09950-00020, 09950-60010 (09951-00320)
  NOTE: Be careful not to drop the center differential assembly.
  
  Fig 3: Removing Front Drive Gear Piece Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT TAPER ROLLER BEARING
Using SST and a press, remove the front taper roller bearing.
1. SST 09950-00020
NOTE: Set the claw of SST to the bearing inner race securely.

Fig 4: Removing Front Taper Roller Bearing Using SST & Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HIGH SPEED OUTPUT GEAR

Fig 5: Removing High Speed Output Gear

REMOVE 2 NEEDLE ROLLER BEARINGS
REMOVE HIGH AND LOW CLUTCH SLEEVE

Fig 6: Removing High & Low Clutch Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HIGH SPEED OUTPUT GEAR BUSHING AND CLUTCH HUB
1. Using SST, remove the high speed output gear bushing and clutch hub.
  1. SST 09950-00020, 09950-00030, 09950-60010 (09951-00320)
  Fig 7: Removing High Speed Output Gear Bushing & Clutch Hub Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a magnetic finger, remove the straight pin from the differential front case.
REMOVE REAR TAPER ROLLER BEARING
Using SST and a press, remove the rear taper roller bearing.
1. SST 09950-00020, 09950-60010 (09951-00320)
NOTE: Set the claw of SST to the bearing inner race securely.

Fig 8: Removing Rear Taper Roller Bearing Using SST & Press
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL REAR CASE
Remove the 12 bolts and differential rear case.

Fig 9: Removing Differential Rear Case & Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE THRUST WASHER AND REAR SIDE GEAR

Fig 10: Removing Thrust Washer & Rear Side Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PINION SHAFT, 2 PINION GEARS AND 2 THRUST WASHERS
1. Remove the straight pin from the pinion shaft.
  
  Fig 11: Removing Straight Pin From Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the pinion shaft, 2 pinion gears and thrust washers.
  
  Fig 12: Removing Pinion Shaft, Pinion Gears & Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the front side gear and thrust washer.
  
  Fig 13: Removing Front Side Gear & Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOW GEAR
Using a plastic hammer, tap and remove the low gear.

NOTE: Be careful not to damage the low gear.

Fig 14: Tapping & Removing Low Gear Using Plastic Hammer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002