Disassembly (Without Electronic Locking Differential)

Using dial indicator, check vertical and lateral runout on companion flange while rotating companion flange. See Figure. Replace companion flange if vertical or lateral runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS .
Using dial indicator, check ring gear runout at backside of ring gear while rotating ring gear. See Figure. Replace ring gear and drive pinion as a set if ring gear runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS .
Using dial indicator, check ring gear backlash while rotating ring gear back and forth while holding drive pinion from rotating. See Figure. Ring gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .
On Tacoma, using dial indicator, check side gear backlash while holding one side gear against differential case. See Figure or Figure .
Side gear backlash should be within specification. See AXLE ASSEMBLY SPECIFICATIONS . If side gear backlash is not within specification, different thickness thrust washer must be installed on side gear.
Using INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque required to start rotation of drive pinion to determine drive pinion bearing preload for reassembly reference. Drive pinion rotating torque should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .
Using INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to rotate drive pinion and ring gear for reassembly reference. Total assembled preload should be within specification. See AXLE ASSEMBLY SPECIFICATIONS .
On all models, check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION.
Using hammer and chisel, loosen staked area on drive pinion nut. Remove drive pinion nut.
Using puller, remove companion flange from drive pinion. Using puller, remove oil seal.
On Tacoma with 2.4L engine, use a puller to remove front bearing from pinion. Remove bearing spacer. Place reference marks on bearing cap and differential carrier. Remove 2 adjusting nut locks, bearing caps and 2 adjusting nuts. See Fig 1. Remove differential case with side bearing outer races from carrier. Mark parts for original locations.
On Tacoma with 2.7L or 3.4L engine, use a puller to remove front bearing. Remove 2 washers and bearing spacer. Place reference marks on bearing cap and differential carrier, and remove bearing cap. See Fig 2. Using removal tool and plastic hammer, remove 2 side bearing plate washers. Measure and record plate washer thickness. Mark bearings for original locations.
On 4Runner, remove oil slinger and front bearing. Place reference marks on bearing cap and differential carrier. Remove 2 adjusting nut locks, bearing caps and 2 adjusting nuts. See Fig 3. Remove differential case with side bearing outer races from carrier. Mark parts for original locations.
On all models, remove drive pinion and bearing spacer (if equipped) from differential carrier. Press rear bearing from drive pinion (if necessary). Remove washer from drive pinion (if equipped). Using hammer and brass drift, tap bearing races and adjusting washers (if equipped) from differential carrier (if necessary). Measure and record adjusting washers thickness (if equipped).
Place reference marks on ring gear and differential case for reassembly reference. Bend over tabs on lock plates (if equipped) on ring gear bolts. Remove ring gear bolts. Using soft-face hammer, tap ring gear from differential case.
Check differential case runout. Reinstall differential case with side bearings and races in differential case. Install side bearing caps and adjusting nuts. Tighten adjusting nuts until no play exists in side bearing. Tighten side bearing cap bolts to specification. See TORQUE SPECIFICATIONS .
Using dial indicator, check differential case runout at ring gear mounting surface on differential case while rotating differential case. Replace differential case if runout exceeds specification. See AXLE ASSEMBLY SPECIFICATIONS . Remove differential case and components from differential carrier.
On all models, use puller to remove side bearings from differential case (if necessary). Fit jaws of puller in case notches.
On Tacoma, use pin punch and hammer to remove straight pin from differential case. See Fig 1 or Fig 2 . Remove pinion shaft, 2 pinion gears, thrust washers and side gears from differential case.
On 4Runner, place reference marks on left and right differential cases. Remove 8 case bolts, loosening evenly in small increments. Using plastic hammer, tap cases to separate them. Remove 2 side gears and thrust washers, spider, 4 pinion gears spider and thrust washers.
On all models, use a press to remove dust deflector.

Fig 1: Exploded View Of Differential Assembly (Tacoma - 2.4L W/O ELD)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 2: Exploded View Of Differential Assembly (Tacoma - 2.7L & 3.4L W/O ELD)

Fig 3: Exploded View Of Differential Assembly (4Runner - W/O ELD)