Differential Case: Disassembly

REMOVE FRONT DIFFERENTIAL RING GEAR
1. Place matchmarks on the ring gear and differential case.
  
  Fig 1: Aligning Matchmarks On Ring Gear And Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 16 bolts.
  
  Fig 2: Identifying Front Differential Ring Gear Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a plastic hammer, tap the ring gear to remove it from the case.
  
  Fig 3: Tapping Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL SIDE GEAR
1. Remove the differential LH case from the differential case assembly.
  
  Fig 4: Identifying Differential LH Case From Differential Case Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 2 differential case from the differential case LH.
  
  Fig 5: Identifying No. 2 Differential Case From Differential Case LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the front differential side gear, front differential side gear thrust washer, conical spring, and center differential side gear thrust washer No. 2 from the differential case LH.
  
  Fig 6: Identifying Front Differential Side Gear, Front Differential Side Gear Thrust Washer And Conical Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a snap ring expander, remove the pinion shaft spacer snap ring.
  
  Fig 7: Removing Pinion Shaft Spacer Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a pin punch and hammer, remove the 3 straight pins.
  
  Fig 8: Tapping Straight Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the center differential pinion shaft and 2 differential pinion shafts.
  
  Fig 9: Identifying Center Differential Pinion Shaft And Differential Pinion Shafts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the 4 front differential pinions, 4 front differential pinion thrust washers, front differential pinion shaft holder, front differential planetary ring, and No. 1 differential side gear thrust washer.
  
  Fig 10: Identifying Front Differential Pinions And Front Differential Pinion Thrust Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the front differential case rear tapered roller bearing from the differential case.
  SST 09950-00020, 09950-00030, 09950-60010 (09951-00480)
  
  Fig 11: Removing Front Differential Case Rear Tapered Roller Bearing From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case rear tapered roller bearing outer race and differential case washer.
  SST 09308-00010
  NOTE:
  - When replacing the bearing, be sure to replace both outer and inner races.
  - When replacing the bearing, be sure to replace both left and right bearings as a set.
    
    Fig 12: Removing Front Differential Case Rear Tapered Roller Bearing Outer Race And Differential Case Washer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CENTER DIFFERENTIAL PINION
1. Using a "TORX" socket (T50), remove the 15 bolts.
  
  Fig 13: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place matchmarks on the differential intermediate case and differential case.
3. Remove the differential intermediate case from the differential case RH.
  
  Fig 14: Identifying Differential Intermediate Case And Differential Case RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the center differential side gear, conical spring washer, and center differential side gear thrust washer No. 1 RH from the differential case RH.
  
  Fig 15: Identifying Center Differential Side Gear, Conical Spring Washer, And Center Differential Side Gear Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the differential spider, 5 center differential pinions, and 5 center differential pinion thrust washers from the differential intermediate case.
  
  Fig 16: Identifying Differential Spider And Center Differential Pinions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the front differential case front tapered roller bearing from the differential case.
  SST 09950-00020,09950-00030
  
  SST 09950-60010 (09951-00600)
  
  Fig 17: Removing Front Differential Case Front Tapered Roller Bearing From Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case front tapered roller bearing outer race and differential case washer.
  SST 09308-00010
  
  Fig 18: Removing Front Differential Case Rear Tapered Roller Bearing Outer Race And Differential Case Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSAXLE HOUSING OIL SEAL
1. Using SST, remove the oil seal.
  SST 09950-70010 (09951-07100)
  
  SST 09649-17010
  
  Fig 19: Removing Transaxle Housing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
1. Using SST, remove the oil seal.
  SST 09950-70010 (09951 -07100), 09608-10010
  
  Fig 20: Removing Differential Side Bearing Retainer Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002