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Differential Assembly (A-241/243 Series): Disassembly

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 1994 Toyota MR2, 1993 Toyota MR2, 1993 Toyota Celica, 1992 Toyota MR2, and 1992 Toyota Corolla. However, it is still accessible from the selected car via links, so may be relevant.
  1. Use a dial indicator to measure differential end play. End play should be .0071-.0323" (.180-.820 mm). See Fig 1. Remove 2 oil seal rings from ring gear mounting right case. Remove snap ring and speedometer drive gear.
  2. Place match marks on ring gear mounting left case and right case. Remove bolts and left case. Place match marks on ring gear and left case. Place left case on A/T Tool Set (09350-32014). Using a plastic hammer, remove ring gear from left case.
  3. Remove No. 2 thrust washer. Remove front differential left case from ring gear mounting right case.
  4. Using a Torx wrench, remove screws from left case. Separate left and right cases. DO NOT  scratch contact surface of needle bearing.
  5. Remove the following parts from front differential cases: on A-241H, remove differential pinion shaft and shaft pin. On both models, remove 2 differential side gears and 2 side thrust washers.
  6. Remove No. 1 thrust washer. Check operation of clutch pistons. Plug one hole in right case with your hand. Apply compressed air into other hole and confirm pistons move. See Fig 2.
    Fig 1: Checking Differential End Play
    G93J25782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Checking Operation Of Differential Clutch Pistons
    G93A25783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Remove hydraulic multi-plate clutch discs and plates. Remove snap ring. Remove flange, discs and plates. Using Spring Compressor (09350-32014), compress return spring. Remove snap ring. Apply compressed air to right case hole. Remove No. 1 piston. Remove "O" ring from No. 1 piston. Using small screwdriver, remove reaction sleeve and No. 2 piston. Remove 3 "O" rings from reaction sleeve and No. 2 piston.
  8. Using Bearing Remover and Attachment (09950-00020, 09950-00030), remove ring gear mounting left case bearing. Using A/T Tool Set (09350-32014) and arbor press, install ring gear mounting left case bearing.
  9. Using a chisel and hammer, cut out ring gear mounting right case bearing cage. DO NOT  damage right case. Using A/T Tool Set (09350-32014) and arbor press, remove bearing inner race. Using Bearing Replacer (09316-60010) and arbor press, install new ring gear mounting right case bearing.
  10. Use hammer and brass bar to drive out inner race and plate from left bearing retainer. Place plate into left bearing retainer. Use A/T Tool Set (09350-32014) and arbor press to install outer race and plate or shim.
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