Center Differential: Disassembly

CHECK HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE
1. Using a feeler gauge, measure the high speed output gear thrust clearance.
  
  Fig 1: Measuring High Speed Output Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard clearance: 0.10 to 0.25 mm (0.0039 to 0.0098 in.)
  
  Maximum clearance: 0.25 mm (0.0098 in.)
  
  If the clearance is greater than the maximum, replace the high speed output gear, needle roller bearing, high speed output gear bush low gear, clutch hub or front differential case.
2. Using a dial indicator, measure the high speed output gear radial clearance.
Fig 2: Measuring High Speed Output Gear Radial Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard clearance: 0.035 to 0.091 mm (0.00138 to 0.00358 in.)

Maximum clearance: 0.091 mm (0.00358 in.)

If the clearance is greater than the maximum, replace the high speed output gear, needle roller bearing, high speed output gear bush low gear, clutch hub or front differential case.
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.
Fig 3: Identifying Front Drive Gear Piece
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09950-00020, 09950-60010 (09951-00320)

NOTE: Be careful not to drop the center differential assembly.
REMOVE FRONT TAPER ROLLER BEARING
1. Using SST and a press, press out the taper roller bearing.
Fig 4: Identifying Front Taper Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09950-00020

NOTE: Set the claw of SST to the bearing inner race securely.
REMOVE HIGH SPEED OUTPUT GEAR
REMOVE NEEDLE ROLLER BEARING

Fig 5: Identifying Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HIGH AND LOW CLUTCH SLEEVE

Fig 6: Identifying High And Low Clutch Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HIGH SPEED OUTPUT GEAR BUSH AND CLUTCH HUB
1. Using SST, remove the high speed output gear bush and clutch hub.
  
  Fig 7: Identifying High Speed Output Gear Bush And Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-00020, 09950-00030, 09950-60010 (09951-00320)
2. Using a magnetic finger, remove the straight pin from the front differential case.
REMOVE REAR TAPER ROLLER BEARING
1. Using SST and a press, press out the taper roller bearing.
Fig 8: Identifying Rear Taper Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09950-00020, 09950-60010 (09951-00320)

NOTE: Set the claw of SST to the bearing inner race securely.
REMOVE REAR DIFFERENTIAL CASE
1. Remove the 12 bolts and differential case.
Fig 9: Identifying Rear Differential Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE THRUST WASHER AND REAR SIDE GEAR

Fig 10: Identifying Thrust Washer And Rear Side Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PINION SHAFT, PINION GEAR AND THRUST WASHER
1. Remove the straight pin from the pinion shaft.
  
  Fig 11: Identifying Straight Pin And Pinion Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the pinion shaft, 2 pinion gears and 2 thrust washers.
  
  Fig 12: Identifying Pinion Shaft, Pinion Gears And Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the front side gear and thrust washer.
Fig 13: Identifying Front Side Gear And Thrust Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOW GEAR
1. Using a plastic-faced hammer, tap out the low gear.
Fig 14: Identifying Low Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Be careful not to damage the low gear.