Differential Assembly: Disassembly

WARNING: This page is about a different car, the 2001 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

Remove differential carrier cover. Using dial indicator, check companion flange vertical and lateral runout. Runout should not exceed .0039" (.10 mm). See Fig 1.

Fig 1: Checking Companion Flange Vertical & Lateral Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque. This will determine drive pinion bearing preload for reassembly reference. Drive pinion rotating torque should be within specification. See AXLE ASSEMBLY SPECIFICATIONS table.
Using dial indicator, check ring gear runout at backside of ring gear while rotating ring gear. See Fig 2. Replace ring gear if ring gear runout exceeds .0028" (.071 mm).
Using dial indicator, check ring gear backlash while rotating ring gear back and forth, and holding drive pinion from rotating. See Fig 2. Check ring gear backlash at 3 different areas on ring gear. Ring gear backlash should be .0051-.0071" (.129-.180 mm). If not, adjust side bearing preload or replace components as necessary.
On all differentials check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION.
On models equipped with conventional rear differential, use dial indicator to check side gear backlash while holding one side gear against differential case. See Fig 2. Side gear backlash should be .0020-.0079" (.050-.201 mm). If side gear backlash is not within specification, different thickness thrust washers must be installed on side gears.

Fig 2: Checking Typical Ring Gear Runout, Ring Gear Backlash & Side Gear Backlash
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 3: Exploded View Of Rear Differential Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 table.
Remove companion flange and oil seal from differential carrier. See COMPANION FLANGE & OIL SEAL under REMOVAL & INSTALLATION. Remove oil slinger from front bearing. Remove spacer from drive pinion.
On LSD models, use special puller to remove both side gear shafts from differential. With screwdriver, remove snap rings from both shafts. On conventional rear differential, use needle nose pliers to remove snap rings from inside differential carrier to remove side gear shafts. Remove shafts.
Place reference marks on differential carrier and bearing caps. Remove both bearing caps. See Fig 3.
Using side bearing replacer and a hammer, remove 2 side bearing plate washers. Measure and record thickness of plate washers. Remove differential case. Mark location of side bearing outer races for reassembly reference. Remove side bearing outer races from carrier.
Remove drive pinion from differential carrier. Press front bearing from drive pinion (if necessary). Using hammer and brass drift, remove bearing races from differential carrier.
Place reference marks on ring gear and differential case. Unstake and remove ring gear bolts. Using soft-face hammer, tap ring gear from differential case. Using puller, remove side bearings from differential case (if necessary).

NOTE: On models with Limited Slip Differential (LSD), manufacturer does not recommend disassembly of differential case.

If disassembling differential case on models equipped with conventional rear differential, drive straight pin from ring gear bolt side of differential case. Remove pinion shaft, side gears, pinion gears and thrust washers. On all models, remove dust cover from side gear shafts (if necessary).