Differential Assembly (Tundra): Disassembly

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 .
Using dial indicator, check side gear backlash while holding one side gear against differential case. See 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.
Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION.
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 .
Using hammer and chisel, loosen stake area on drive pinion nut. Remove drive pinion nut.
Using puller, remove companion flange from drive pinion. Using puller, remove oil seal from differential carrier. Using puller, remove front bearing from drive pinion.
Remove washers and spacer from drive pinion. Place reference mark on side bearing cap assembly and differential carrier for reassembly reference. See Fig 1. Remove bolts and side bearing cap assembly.
Remove plate washers from each of side bearings. Plate washers are located between bearing race for side bearing and differential carrier. Mark plate washer location and record thickness for reassembly.
Remove differential case with bearing races for side gears from differential carrier. Mark bearing race location for reassembly reference. Remove drive pinion from differential carrier.
Press rear bearing from drive pinion (if necessary). See Fig 1. Using hammer and brass drift, tap bearing races from differential carrier (if necessary).
Adjusting washer is located between bearing race for rear bearing and differential carrier. See Fig 1. Remove adjusting washer from differential carrier. Measure and record adjusting washer thickness for reassembly reference.
Place reference mark on ring gear and differential case for reassembly reference. 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 cap assembly. Install and tighten side bearing cap assembly 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 from differential carrier. Using puller, remove side bearings from differential case (if necessary).
If disassembling differential case, drive pin from ring gear bolt side of differential case. Remove pinion shaft, side gears, pinion gears and thrust washers. See Fig 1. Using press, press dust deflector from companion flange (if necessary).

Fig 1: Exploded View Of Differential Assembly (Tundra)